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AL8000HT Service Manual-116478-07-28-08

1. Title Part No TEREX AL8000HT Operator s Manual 114426 First Edition TEREX AL8000HT Part s Manual 116447 First Edition TEREX AL8000HT Service Manual 116478 First Edition Newage Generator Manual 830001 Leroy Somer Manual 116118 Isuzu Engine Manual 116133 Kubota Engine 893020 Axis Manual 116117 Marathon Manual 116188 x AL8000HT Light Tower PartNo 116478 September2008 Please be prepared with the following information when ordering replacement parts for your TEREX product Machine modelnumber Machine serialnumber Terex partnumber Part description and quantity Purchase order number Ship to address Desired method of shipment Name and telephone number of the authorized TEREX Distributor in your area FI FI I FI l I Fl E Use the Service Parts Fax Order Form on the next page and fax your order to our Parts Department If you don t know the name of your authorized distributor or if your area is not currently serviced by an authorized distributor please call TEREX Corporation Machine Information Model Serial Number Date of Purchase Authorized TEREX Distributor Phone Number TEREX
2. 3 17 B 9 Perform Axle Maintenance 3 17 A ChecklistC Procedures C 1 Inspect the Tower Extend Retract Cables and Pulleys 3 19 2 Perform Engine Maintenance 3 19 C 3 Perform Axle Maintenance 3 20 C 4 Perform Engine Maintenance Isuzu Models 3 20 C 5 Perform Engine Maintenance Kubota Models 3 21 A ChecklistDProcedures D 1 Perform Engine Maintenance Kubota Models 3 22 D 2 Check the Tower Rotation Bearing Bolts 3 22 D 3 Replace the Hydraulic Return Filter u 3 23 D 4 Perform Engine Maintenance Isuzu Models 3 24 PartNo 116478 AL8000HT Light Tower vii TEREX September2008 TABLE OF CONTENTS D 5 Perform Engine Maintenance Isuzu Models 3 24 0 6 Perform Engine Maintenance 3 25 Section 3 Rev Section 4 Rev Scheduled Maintenance Procedures continued D 7 Perform Generator Maintenance 2 3 25 D 8 Perform Tongue Jack and Outrigger Jack Maintenance
3. variable speed mechanical Valve clearance cold Intake 0 0157 in 0 4 mm Exhaust 0 0157 in 0 4 mm Lubrication system Oil pressure hot 1800 rpm 64 psi 4 4 Oil capacity 7 08 quarts including filter 6 7 liters Oil pressure switch 14 psi engine shut off pressure 0 96 bar Oil viscosity requirements Units ship with 10W 30 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operating Instructions on your machine For fuel requirements refer to the engine Operator s Manual on your machine Battery Type 12V DC Group 27TM Quantity 1 Cold cranking ampere 630 Reserve capacity 25A rate 105 minutes Alternator Output 35A 12V DC Fan belt deflection 1 4 to 3 8 inch 7to9mm Continuous improvement of our products isa Terex policy Product specifications are subject to change without notice 2 6 AL8000HT Light Tower Part No 116478 September 2008 Section 2 Specifications TEREX REVA SPECIFICATIONS Leroy Somer LSA37M7 Generator Generator speed full load 60 Hz 1800 rpm Temperature ambient maximum 104 F 40 C Power 8 kW Capacitor disconnected 100 uF 240V Marathon 201CSA5412 Generator Generator rpm full load 60 Hz 1800 rpm Temperature ambient maximum 104 F 40 C Power 8 kW Newage BCI164D1J195A Generator Generator rpm full load 60 Hz 1800
4. tape don I x n How p 71 11 I Aa NINO va YOLOW 1 1 H3MOL 293979 14 NOISN31X3 _ H3dNITAS L47 baie 6 15 AL8000HT Light Tower PartNo 116478 Section 6 Schematics September2008 TEREX REV A This page intentionally left blank 6 16 AL8000HT Light Tower PartNo 116478 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Towing Checklist Use at each stop Before Towing Boom hold down latch is securely locked in place Towing hitch is properly secured to tow vehicle Safety chains if required are properly attached and secure chains are crossed below hitch All lights are connected and working Tires are properly inflated Before Driving Fasten safety restraints Properly adjust mirrors On The Road Do not exceed 60 mph 97 km h Obey all local and national towing speed laws Check connections and tire pressure at each stop Slow down for hazardous conditions Allow extra distance for following and passing other
5. 3 3 3 3 HHBE BLACK BLACK BLACK BLACK OL 931 WMLTGN OL SLIM WOLRENID 20 3GISNISST AOZT OL WOLYNES 40 3QISNI AOZT OL NOVIA GREEN 8 1SVTIV8 GREEN 4 1SVTIV8 T 9 1SVTIV8 4 5 1SVTIV8 WHITE XO8 1SVTIV8 RED YELLOW 4 2 1SVTIV8 T 1SVTIV8 COIL CORD MAST COIL CORD TO MAST PartNo 116478 AL8000HT Light Tower 6 13 Section 6 Schematics September2008 TEREX Receptacle Wiring Diagrams REV Standard Receptacle Package BREAKER E u BREAKER a 20 Nt RED FROM CONTROL g E BLACK BOX N 120V 20AMPGFI 9 1 RECEPTACLES ey RECEPTACLE J 30A m 542 GREEN FROM CONTROL white BOX M 1 Extra GFCI Receptacle Package 7 777 BREAKER 30A a t BREAKER 20 RED FROM
6. Serial Number Legend MANUFACTURED BY FABRIQUE TEREX 590 Huey Road Rock Hill SC 29732 USA TEREX MODEL SERIAL XXXXXXXXXX 999999 NUMBER V I N NUMBER WEIGHT RATED GENERATOR OUTPUT Position 41 VOLTS Position 35 AC FREQUENCY Position 42 PHASES Position 43 MODEL YEAR 9999 MANUFACTURE 99 99 99 DATE MACHINE UNLADEN 99 999 Ibs 99 999 kg RATED Position 44 CURRENT ELECTRICAL SCHEMATIC Position 3 ETL CERTIFICATION 1 Position 45 ETL CERTIFICATION 2 Position 46 W Listed P N 77172 3057837 AL8XXXXX Serial number is stamped into frame PartNo 116478 AL8000HT Light Tower ili Section 1 Safety Rules September2008 TEREX Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the Terex AL8000HT Operator s Manual on your machine will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless Youaretrained and qualified to perform maintenance on this machine You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop
7. 3 26 D 9 Perform Axle Maintenance 3 26 Testor Replace the Hydraulic 3 27 E 2 Perform Engine Maintenance Kubota 3 28 E 3 Perform Engine Maintenance Kubota 3 29 E 4 Perform Generator 3 29 E 5 Perform Generator Maintenance 3 30 Repair Procedures uuu Em 4 1 Lighting Med 4 2 Light Bar Components MEE ED d 4 4 2 2 Light Bar Lift Cylinder a 4 5 Tower Components 31 Plastic Cable Track dened Sees 4 7 X2 TOWSCASSOMDIY 5 0 uya ine 4 7 3 3 Tower Lift Cylinder a 4 10 3 4 Tower Extension Cylinder 4 11 3 5 TowerRotation Motor 4 12 Kubota D1105 E V1505 E Engine 41 Timing Adjustment U U eene nemen 4 13 4 2 GOW c EE 4 13 4 3 Coolant Temperature and Oil Pressure Switches 4 13 Isuzu 4LE1 Engine 5 1 Timing 4 14 vill AL8000HT Light Tower Part No 116478 September2008 TER
8. Part No 116478 AL8000HT Light Tower 6 11 September2008 Section 6 Schematics TEREX AC Electrical Schematic REV Autostart Models with 6 Lights LOWER RECEPTACLE BOX UPPER RECEPTACLE BOX Y 3TOv1d303N 30d 9 1SVTIV8 9 1SVTIV8 159 4 31OV1d393 9109 Wada 8 OZ Wada 0L MA SL MLW 9 ZL MOS 7 01 8 Ld393M N39 3215 3HIM le 159 lo I1SVTIV8 lOHINOO L LsvTiva 3ZIS H33V3S8 AL8000HT Light Tower PartNo 116478 6 12 September2008 Section 6 Schematics TEREX AC Electrical Schematic REV Autostart Models with 8 Lights eosescee TO RECEPTACLES SWITCHES 1 ES leeeoceeeoe 36 MTW 8 EPDM 12 KW 15 KW 10 EPDM 20 KW RED BLACK fex n Lu tr amp 9 N 2 x z 50A 60A 80A gt lt mi r4 E a a 12 KW 15 KW MAIN BREAKER SIZE 20 KW Eso rss 55 s 29
9. 8 x ir BLACK 120V 120V 20 AMP GFI 20 GFI RED RECEPTACLES RECEPTACLES MT RECEPTACLE 30A GREEN CONTROL Pe _ _ _ __ _ _ _ _ ire id BREAKER 7 T 30A 8 x m BREAKER BREAKER 30A 30A BREAKER RED a 20 CONTROL u x u u x BOX m m E a BLACK 120V 120V 20 AMP GFI 20 AMP GFI RED RED p RECEPTACLES RECEPTACLES MA seems 30A GREEN FROM CONTROL 240V RECEPTACLES 6 14 AL8000HT Light Tower PartNo 116478 TEREX Hydraulic Schematic Section 6 Schematics September2008 REV MIOSINVW NOILONNA DE OS ISd 0026 ur it eu rc Yad LOVYLAY 1 woog woog NMOG woog woog NS 1 RH H L K rA 1 es 1oVHldH QN31X3 1331 1H9lH 3lviou 3iviou YAGNINAO H3dNITA9 woog woog 1 154 0002
10. 9 N3dO c indinouaisvis S N3dO rL Ti2010Hd f N3dO L dW3L1NYVIOOOHSIH Z ANALNO Tans LL NadO L ALNOAV1 NOLLISOd N3SVNAQ 2891 YJJWNN LHVd SS3NHVH VLOS M MISHA sena oN Wnd m 3univs3dWal Tana 1Nv1002 999 HOIH 5 man maf ma o elle ng ouo 8 980 elle 6 5 8 8 3unssaud 710 MOT A a 9 s elle KR s s elle D e le 940 D LHM elle E D z ouo E e le tH J 11 5 52676 2 GION3 OS z 1913 x m s a NOlLdO e E LHM 90183 1545 1545 1595 AV T3 AZL Av T3 JIE 1 ZL EW 18 AYALIVE lt A 5 ue NIV p 4 mo oe oo ee ee am eS SILN3NOdMWOO 3NION3 AL8000HT Light Tower PartNo 116478
11. TABLE OF CONTENTS 4 Perform Engine Maintenance Isuzu Models 3 9 Section 3 Rev Scheduled Maintenance Procedures continued A 5 Perform Generator Maintenance 3 9 6 PerformAxie Maintenance 3 10 7 Perform 30 Day Service c o 3 10 8 Perform Engine Maintenance 3 11 9 Perform Hitch Maintenance 3 11 A 10 Grease the Turntable RotationBearing and Rotate Gear 3 12 A 11 Perform Engine Maintenance Kubota Models 3 13 A 12 Perform Engine Maintenance Kubota Models 3 13 A Checklist B Procedures rispect the BAe ry ana bass 3 14 B 2 Inspectthe Electrical Wiring 3 14 B 3 Inspect the Tires and Wheels including lug nuttorque 3 15 B 4 Perform Hydraulic Oil 3 15 B 5 Perform Engine Maintenance Isuzu Models 3 16 B 6 Perform Generator Maintenance 22 3 16 B 7 Perform Hitch Maintenance UI 3 17 B 8 Perform Engine Maintenance Kubota Models
12. remove the cap item H Adjust the internal hex socket Turn it clockwise to increase the pressure or counterclockwise to decrease the pressure Install the relief valve cap Component damage hazard Do not adjust the relief valve higher than specified Repeat steps 3 through 6 and recheck relief valve pressure Remove the pressure gauge 4 24 AL8000HT Light Tower Part No 116478 September2008 Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on a firm level surface Wheels chocked Toggle switch in off position All circuit breakers in the off position Section 5 Troubleshooting TEREX Troubleshooting Before Troubleshooting M Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Be aware of the following hazards and follow generally accepted safe workshop practices Use only a voltmeter with insulated probes rated at a minimum of 600V AC
13. 120 135 160 18 L 140 158 NE nn REEL ft lbs Nm ft lbs Nm ftibs Nm ftibs Nm ftibs Nm 5 16 24 114 9 j 19 257 2 271 2 366 24 325 3 8 2 352 35 474 37 501 49 664 43 593 76 L14 37 501 49 664 50 678 70 947 61 827 201 41 555 55 745 60 813 1084 68 921 42 L dA3 57 773 75 1016 80 1084 110 149 93 12 _ 22 64 867 85 115 90 122 120 162 j 105 142 gi L1 80 1084 110 149 120 162 150 203 130 1 6 180 90 122 j 120 162 j 130 76 7 0 230 j 140 189 10 20 21 270 366 280 379 515 320 43 46 220 298 300 406 310 420 420 569 350 474 7g L9 32 433 430 583 450 610 610 827 50 6941 8 480 650 640 867 680 92 90 1233 0 1044 12 530 718 710 962 750 1016 990 1342 840 1139 1 6 1460 1979 1950 2643 2370 3213 3160 4284 260 3620 2 FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Class 4 6 Class 8 8 Class 10 9 Class 12 9 RY DRY D DRY LUBED DRY N 3 E N EN r c B NI C2 o O1 gt E N oJ Hc j c gk D D
14. Allow lamps to cool before opening the fixtures ADANGER Electrocution hazard Exposure to high voltage electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Turn off all power when not needed for testing Use extreme caution when working with high voltage electrical components ADANGER Electrocution hazard Attempting to sevice the machine before the capacitors are fully discharged will result in death or serious injury AWARNING Electrocution hazard Exposure to electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry ACAUTION Burn hazard Contact with hot engine components may cause severe burns Use caution when working around a hot engine PartNo 116478 AL8000HT Light Tower 5 1 Section 5 Troubleshooting September 2008 TEREX REVA Troubleshooting Guide The engine generator set is tested and set at the factory for proper operation in the field These units should never require additional adjustments in the field If needed adjustments should only be made by a qualified service technician otherwise the manufacturer s warranty may become void TROUBLE POSSIBLE CAUSE REMEDY 1 Boom will not rise to the operating position b Defective cable b Have a trained or pulley mechanic examine and repair as needed 2 Boom will not telescope a Problem with hydraulics a Trouble sh
15. September2008 TEREX GENSET TORQUE SPECIFICATIONS Generator Flex Plate to Flywheel Generator Case to Bellhousing Genset Isolators 2 10 AL8000HT Light Tower PartNo 116478 September2008 Section 3 Scheduled Maintenance Procedures TEREX Scheduled Maintenance Procedures Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed daily quarterly semi annually annually and every 2 years as specified on the Maintenance Inspection Report AWARNING Failure to perform each procedure as presented and scheduled could result in death serious injury or substantial damage Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Use only Terex approved replacement parts Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Unless otherwise specified perform each maintenance procedure with the machine in the following configuration Machine parked on firm level surface Key switch in the off position manual start models Toggle switch in the off position automatic start models Mastin the stowed position Light switches in the off position Wheels chocked Abo
16. How To Order Parts Genie Industries 18340 NE 76th Street P O Box 97030 Redmond WA 98073 9730 Telephone 877 367 5606 Fax 888 274 6192 genieindustries com Part No 116478 AL8000HT Light Tower xi TEREX September2008 Service Parts fax Order Form FAX TO 888 274 6192 OR TOLL FREE 877 367 5606 Please fill out completely Date Account Number Your Name Your Fax Number Your Phone Number Bill To Ship To Purchase Order Number Ship Via Model s Serial No s Optional Equipment Part Number Price All backordered parts will be shipped when available via the same ship method as the original order unless notedbelow Ship complete order only no backorders o Ship all available parts and contact customer on disposition of backordered parts o Other please specify For TEREX Use ONLY Order Number Date Scheduled Order Total Origin Code Comments Ship Condition 27 77 Terms Code remove this page and make copies remove this page and make copies September2008 REV A Machine Specifications Section 2 Specifications TEREX Specifications Performance Specifications Lights Tongue weight maximum 350 Ibs 159 kg Type BT 37 Metal Halide 1000 watt __ _ Run time full load Total lighting wattage Kubota D1105 8kW 82 Gallons per hour
17. September2008 Section 6 Schematics TEREX IC AC Electrical Schemat REV A Standard Models with 4 Lights BA VIE FREEZE 1 5 5 9 B NYO 310vid3o3 3104 a 2 ayoo y BA vi amp 718 NYO 5 ama m TBX NYO SKM 33x dau vis 75 TBA bE gt FREEZE N332I9 9 NYO v4 m eo w w m B Jn xog 3 IOVLd3O3H dau vis iv 1 6 TSA VE S3HOLIMS 1H9n NYO v4 aH LSVTIVd YOLVYANAD 40 3qISNI 931 TVd1n3N OL S315v1d3938 OL HO1VWU3N39 3O 3qISNI ANNOYS OL N3385 YOLVYAANSD dO AGISNI 931 AOZT OL YOLVYANSD dO AGISNI 931 AOZT OL cau NIVW Ovid Wada 8 02 Wada 0l SL MLW 9 ZL MOS 7 0 8 193999 8 N39 3ZIS SHIM qas V08 OZ V09 MA SL WOE 8 3ZIS NIV Part No 116478 AL8000HT Light Tower TEREX AC Electrical Schematic Standard Models with 6 Lights Section 6 Schematics September2008
18. 116478 REV A September2008 Section 6 Schematics Control Box and Engine DC Electrical Schematic Kubota Models TEREX oN P 1NV1002 T HOIH 1 1 a YILIN T l offo L 2 0t 0L H i oN 8 219 T NUS 9 0553 L 4 4 9 s es elle v v elle o o z z L L GION310S x o 1 a 9 K E 40163 i m Nua afo o 1545 76 5 AZL 1 LOA ZL 1222 4 GSu LHM u _ o O oje TA 1 z 1 1H9h 1 NM ET RET au 222225052222 2 NU OLET MN SLNANOdWOD 3NION3 Part No 116478 AL8000HT Light Tower TEREX DC Electrical Schematic Control Box and Engine Section 6 Schematics September2008 with Autostart Option REV 6 89 YASWAN LYYd SS3NSVH NZNSI 6089 YASWNN LYYd SSANYVH VLOSD qNnoso 02 LYVLS WONVA OL s LNdLNO NOOSIQ NIVN 61 LOVINOD H3NIL 6 N3dO 8 LOVINOD H3NIL 8 N3dO ZL 18915010907 NadO 9
19. 4 lights 4000 watts 8 lights 8000 watts Single full fuel tank 36 5 hours Axle Dual full fuel tanks 73 hours Axle load capacity maximum 4200 Ibs Run time full load 1905 kg Kubota V1505 12kW 1 1 Gallons per hour Fluid capacities Single full fuel tank 27 25 hours Hydraulic tank capacity 1 4 gallons Dual full fuel tanks 54 5 hours 5 3 liters Run time full load Hydraulic system capacity 2 gallons Isuzu 4LE1 20kW 1 8 Gallons per hour including tank 7 6 liters Single full fuel tank 16 5 hours Single fuel tank 30 gallons 114 liters Dual full fuel tanks 33 hours Dual fuel tanks 60 gallons Towing speed maximum 62 mph 227 liters 100 km h Tires and wheels U S models Function speeds Tire size ST205 75R15 up 12 to 24 seconds toad Tanga to Boom down 12 to 21 seconds Lug nut torque dry 80 ft Ibs 108 Nm Tire pressure maximum cold 50 psi 3 4 bar Tires and wheels Australia models Tire size 7 5R16 C 112 110L Lug nut torque dry 80 ft Ibs 108 Nm Tire pressure maximum cold 75 psi 5 2 bar For operational specifications refer to the Operator s Manual Boom extend 17 to 37 seconds Boom retract 13 to 27 seconds Light bar up 18 to 30 seconds Light bar down 14 to 24 seconds Tower rotate 359 31 to 68 seconds Continuous improvement of our products is a Terex policy Product specifications are subject to change without notice PartNo 116478 AL8000HT
20. 6 Remove the fasteners securing the power unit to the cabinet Carefully remove the power unit from the curb side of the machine Component damage hazard The hydraulic reservoir is plastic and may become damaged if allowed to fall when removed from the machine 7 Place a suitable container under the hydraulic reservoir Refer to Section 2 Specifications for capacity specifications 8 Remove the hydraulic reservoir retaining fasteners from the power unit Carefully remove the hydraulic reservoir from the power unit and completely drain it into a suitable container Bodily injury hazard Beware of hot ACAUTION oil Contact with hot oil may cause severe burns PartNo 116478 AL8000HT Light Tower 3 27 TEREX CHECKLIST E PROCEDURES 9 Remove the suction strainer and clean it using a mild solvent 10 Rinse out the inside of the reservoir using a mild solvent 11 Install the suction strainer 12 Install the hydraulic reservoir onto the power unit 13 Install the hydraulic reservoir retaining fasteners and securely tighten Do not overtighten 14 Install the hydraulic power unit onto the machine 15 Fill the reservoir with hydraulic oil to within a 1 2 from the top with the cylinders collapsed 16 Clean up any oil that may have spilled Properly discard the used oil 17 Operate all machine functions through a full cycle and check for leaks 18 Operate all machine functions through 5 10 full cycle
21. Light Tower 2 1 TEREX SPECIFICATIONS Hydraulic Oil Specifications Hydraulic Oil Specifications Chevron Rando HD Premium MV Multi viscosity Hydraulic oil type Viscosity grade Viscosity index 200 Cleanliness level minimum 15 13 Water content maximum 200 ppm Chevron Rykon MV oil is fully compatible and mixable with Shell Donax TG Dexron lll oils Genie specifications require hydraulic oils which are designed to give maximum protection to hydraulic systems have the ability to perform over a wide temperature range and the viscosity index should exceed 140 They should provide excellent antiwear oxidation corrosion inhibition seal conditioning and foam and aeration suppression properties Optional fluids Petro Canada Environ MV46 Statoil Hydra Way Bio Pa 32 BP Biohyd SE S Biodegradable Fire resistant UCON Hydrolube HP 5046 Quintolubric 822 Shell Tellus T32 Shell Tellus T46 Chevron Aviation A Mineral based Continued use of Chevron Aviation A hydraulic fluid when ambient temperatures are consistently above 32 F 0 C may result in component damage Note Use Chevron Aviation A hydraulic fluid when ambient temperatures are consistently below 0 18 C Note Use Shell Tellus T46 hydraulic oil when oil temperatures consistently exceed 205 F 96 C Note Terex specifications require additional equipment and special installation instructions for the approved optional
22. Priority flow regulator valve 0 2 0 76 L MIN Due Light bar up down circuit 20 ft lbs 27 Nm 7 Orifice plug 0 025 inch 0 64 mm Een Tower rotate circuit PartNo 116478 AL8000HT Light Tower 4 23 TE RE x Section 4 Repair Procedures September2008 CHASSISCOMPONENTS REV 8 2 Use a wrench to hold the relief valve and Valve Adjustments Function Manifold How to Adjust the Tower Rotate Relief Valve Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the tower in the stowed position 1 Disconnect and plug the hydraulic hose from the P port at the function manifold Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Connect a 0 to 5000 psi 0 to 350 bar pressure gauge to the P port of the function manifold using a tee fitting Install the hose to the tee fitting 3 Activate and hold the tower rotate toggle switch in either direction 4 Observe the pressure reading on the pressure gauge Refer to Section 2 Specifications
23. REV LOWER UPPER 3104 915 9 ISVTIV8 3T0v1d303u 104 Wada 8 02 Wada 0L MA SL MALIN 9 MA ZL MOS OL 8 Ld3O3M 9 N39 3215 m e SE n o vl1SVTIV8 x i Lej 9 ISVTIVH lt a o x Z ISVTIV8 LiSvTivg NOLO3NNOO 9 13S 8409 9 9 quoa vos Moe 3ZIS H3XV3MH8 NIVIN Xog IlOHLINOO AL8000HT Light Tower PartNo 116478 REV September2008 Section 6 Schematics AC Electrical Schematic Standard Models with 8 Lights TEREX 815 2 15 91SVTIV8 S ISVTIVS Co 31Ov1d393 104 le 4 1SVTIV8 RECEPTACLE BOX le 159 1199 ls AL8000HTLightTower z LSVTIVE 1 3104 RECEPTACLE BOX mi ISVTIV8 Wada 8 MM
24. available in the Isuzu 4LE1 Diesel Engine Instruction Manual Isuzu part number IDE 6033 OR the Kubota D 1105and V 1505 Operator s Manual Kubota part number 16683 89169 Isuzu 4LE1 Diesel Engine Instruction Manual Terex part number 116133 Kubota D 1105 and V 1505 Operator s Manual Terex part number 893020 PartNo 116478 AL8000HT Light Tower TEREX CHECKLIST PROCEDURES C 3 Perform Axle Maintenance Note Axle specifications require that this procedure be performed every 6 months or 6000 miles whichever comes first Proper axle maintenance following the axle manufacturer s maintenance schedule is essential to good axle performance and service life Failure to perform the maintenance procedures can lead to poor axle performance and component damage Required maintenance procedures and additional axle information is available in the Axis Axle Operator Maintenance Manualincluded with your machine Axis Axle Operator Maintenance Manual Terex part number 116117 Section Scheduled Maintenance Procedures September 2008 REVA 4 Perform Engine Maintenance Isuzu Models Note Engine specifications require that this procedure be performed every 750 hours Required maintenance procedures and additional engine information is available in the Isuzu 4LE1 Diesel Engine Instruction Manual Isuzu part number IDE 6033 Isuzu 4LE1 Diesel Engine Instruction Manual Terex part numbe
25. fluids Consult the Terex Service Department before use Section 2 Specifications September 2008 REVA Hydraulic Component Specifications Function pump Type Fixed displacement gear pump Displacement 0 056 cu in per revolution 0 92 cc Flow rate 3200 psi 0 6 gpm 2 27 L min System relief pressure 3200 psi 220 6 bar Function manifold Light bar up down 0 2 gpm flow regulator 0 76 L min Tower rotate relief 1200 psi valve pressure 82 7 bar Hydraulic filter Hydraulic tank return filter Beta 10 gt 200 with 25 psi 1 7 bar bypass Continuous improvement of our products is a Terex policy Product specifications are subject to change without notice 2 2 AL8000HT Light Tower Part No 116478 September2008 REV Manifold Component Section 2 Specifications TEREX SPECIFICATIONS Machine Torque Specifications Specifications Tower rotation assembly Plugtorque Rotate bearing mounting bolts lubricated 1 2 T SAE No 2 36 in Ibs 4 Nm 2 13 SHC bolts 95 ft lbs 129 Nm SAE No 4 10 ft lbs 13Nm 8 11 SHC bolts 195 ft lbs 264 Nm SAE No 6 14 ft lbs 19 Nm Rotation motor mounting bolts dry 75 ft Ibs SAE No 8 38 ft Ibs 51 Nm 1 2 13 GR 5 102 Nm SAE No 10 41 ft Ibs 55 Nm Rotation motor mounting bolts lubricated 57 ft Ibs 12 13 GR 5 77 Nm SAE No 12 56 ft Ibs 76 Nm Generator Valve Coil Resistance Ge
26. fray Always wear adequate hand protection when handling the cable Component damage hazard Cables can be damaged if they are kinked or pinched Note During removal the overhead crane strap will need to be carefully adjusted for proper balancing Note As the number 2 and 3 tower tubes are removed from the number 1 tower tube guide the retract cable out from the slot in the bottom of the number 1 tower tube 13 Working at the extension end of the number 2 tower tube remove the cotter pins from the two clevis pins that surround the cable pulley Remove the clevis pins Do not remove the pulley clevis pin Note Always use a new cotter pin when installing a clevis pin PartNo 116478 AL8000HT Light Tower 4 9 TEREX TOWERCOMPONENTS 14 Pull the extend cable free of the pulley mount and lay it flat on top of the number 3 tower tube Bodily injury hazard Cables can ACAUTION fray Always wear adequate hand protection when handling the cable 15 Label and remove the wear pads from the extension end of the number 2 tower tube 16 Attach a lifting strap from an overhead crane to the number tower tube 17 Support and slide the number 3 tower tube from the number 2 tower tube and place itona structure capable of supporting it Crushing hazard The number 2 AWARNING and 3 tower tubes could become unbalanced and fall when removed from the number 1 tube if not properly supported by the overhead crane B
27. from the machine and place it on a structure capable of supporting it Crushing hazard The tower AWARNING assembly could become unbalanced and fall when removed from the machine if not properly supported and secured to the forklift Section 4 Repair Procedures September 2008 REVA How to Disassemble the Tower Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Remove the tower assembly See 3 2 How Remove the Tower Assembly 2 Tag disconnect and plug the light bar lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 3 Attach a suitable lifting device to the light bar cylinder 4 Remove the pin retaining fasteners from the light bar link pivot pin Use a soft metal drift to remove the pin Remove the cylinder from the tower assembly with links and levers attached Note There is a spacer tube between the two links that may fall out when the pivot pin is removed 5 Remove the cable retaining nut from the extend cable at the extension end of the tower located near the extend cylinder rod end pivot p
28. guides the cables and hoses running up the tower It can be repaired link by link without removing the cables and hoses that run through it Removing the entire tower cable track is only necessary when performing major repairs that involve removing the tower How to Repair the Plastic Cable Track Componentdamagehazard The tower cable track can be damaged if it is twisted a link separation point b lower clip 1 Useaslotted screwdriver to pry down on the lower clip 2 Repeat step 1 for each link 3 Toremove a single link open the lower clip and then use a screw driver to pry the link to the side Section 4 Repair Procedures TEREX TOWER COMPONENTS 3 2 Tower Assembly How to Remove the Tower Assembly AWARNING P dily injury hazard The procedures in this section require specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools could result in death or serious injury and significant component damage Dealer service is required Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Removethe light bar See 2 1 How to Remove the Light Bar Assembly 2 Remove the cable track tube retaining fasteners atthe number 3 tower tube 3 Remove the hose and cable
29. is completed Follow the instructions in the operator s manual If any inspection receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes completed N no unable to complete R repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company Section 3 Scheduled Maintenance Procedures September2008 TEREX This page intentionally left blank 3 4 AL8000HT Light Tower PartNo 116478 September2008 Section 3 Scheduled Maintenance Procedures TEREX Maintenance Inspection Report Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hours Inspection A Quarterly or 250 hours Inspection A B Semi annually or 500 hours Inspection A B C Annually or 1000 hours Inspection A B C D Two year or 2000 hours Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this sec
30. lens mounting fasteners and remove the lens 3 Remove the spring securing the lamp to the lamp retainer Component damage hazard Contacting the lamp with bare skin can cause damage to the lamp Do not allow bare skin contact with the lamps 4 Wrap aclean cloth around the lamp and remove the lamp from the socket Note Be sure to wrap a clean cloth around a lamp when installing a lamp into a lamp socket Section 4 Repair Procedures September 2008 REV How to Check Line Voltage Correct line voltage at the lamp socket is essential for proper operation of the lighting system ADANGER Electrocution hazard Exposure to high voltage electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Turn off all power when not needed for testing Use extreme caution when working with high voltage electrical components 1 Turn off all machine power 2 Remove the cover from the lamp junction box Note The junction box is located between the light housings at the top of the mast 3 Locate the correct wiring for the lamp to be tested 4 Connecta voltmeter to the lamp wires 5 Startthe engine 6 Turn the appropriate circuit breaker light switch to the ON position 7 Observe the voltage as the lamps warm up Refer to the following chart Note It can take up to 5 minutes for the lights to reach full intensity If the lights are turned off and th
31. number 893020 PartNo 116478 AL8000HT Light Tower TEREX Section 3 Scheduled Maintenance Procedures September 2008 Checklist B Procedures B 1 Inspect the Battery Note Terex requires that this procedure be performed every 250 hours or quarterly whichever comes first Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry AWARNING Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 Open the cabinet cover at the curb side of the machine and locate the battery 3 Be sure that the battery cable connections are free of corrosion Note Adding terminal protectors and a corrosion preventative sealant will help eliminate corrosion on the battery terminals and cables 4 that the battery retainers and cable connections are tight REVA B 2 Inspect the Electrical Wiring Note Terex requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining electrical wiring in good condition is essential to safe
32. or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the light bar cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Support the cylinder with a suitable device to prevent it from falling 3 Remove the pin retaining fasteners from both the rod end and barrel end pivot pins 4 Place a rod through the pins and twist to remove Remove the cylinder from the machine PartNo 116478 AL8000HT Light Tower 4 5 TEREX Section 4 Repair Procedures September2008 Tower Components BEER Q O u OOO tower extension cylinder light bar light bar cylinder light bar lever light bar link tower tube number 3 tower tube number 2 tower tube number 1 tower lift cylinder tower rotation riser AL8000HT Light Tower Part No 116478 September2008 REV A 3 1 Plastic Cable Track How to Remove the Cable Track The tower cable track
33. required to perform this procedure Indicates that a cold engine will be requiredto perform this procedure Indicates that a warm engine will be requiredto perform this procedure Indicates that dealer service will be requiredto perform this procedure Section Scheduled Maintenance Procedures September2008 Pre delivery Preparation Report The pre delivery preparation report contains checklists for each type of scheduled inspection Make copies of the Pre delivery Preparation report to use for each inspection Store completed forms as required Maintenance Schedule There are five types of maintenance inspections that must be performed according to a schedule daily quarterly semi annually annual and two year The Scheduled Maintenance Procedures Section and the Maintenance Inspection Report have been divided into five subsections A B C D and E Use the following chart to determine which group s of procedures are required to performa scheduled inspection Inspection Checklist Daily or every 8 hours A Quarterly or every 250 hours A B Semi annually or every 500 hours A B C Annually or every 1000 hours A B C D Two years or every 2000 hours A B C D E Maintenance Inspection Report The maintenance inspection report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Maintain completed forms for a
34. rpm Temperature ambient maximum 104 F 40 C Power 12 kW Newage BCI184E1J203A Generator Generator rpm full load 60 Hz 1800 rpm Temperature ambient maximum 104 F 40 C Power 20 kW Continuous improvement of our products isa Terex policy Product specifications are subject to change without notice PartNo 116478 AL8000HT Light Tower 2 7 TEREX SPECIFICATIONS Section 2 Specifications Hydraulic Hose and Fitting Torque Specifications Your machine is equipped with Parker Seal Lok fittings and hose ends Genie specifications require that fittings and hose ends be torqued to specification when they are removed and installed or when new hoses or fittings are installed SAE O ring Boss Port tube fitting installed into Aluminum SAE Dash size Torque 4 11 ft lbs 14 9 Nm 6 23 ft lbs 31 2 Nm 8 40 ft lbs 54 2 Nm 10 69 ft lbs 93 6 Nm 12 93 ft lbs 126 1 Nm 16 139 ft Ibs 188 5 Nm 20 172 ft lbs 233 2 Nm 24 208 ft Ibs 282 Nm SAE O ring Boss Port September 2008 REVA Seal Lok fittings 1 Replace the O ring The O ring must be replaced anytime the seal has been broken The O ring cannot be re used if the fitting or hose end has been tightened beyond finger tight Note The O rings used in the Parker Seal Lok fittings and hose ends are custom size O rings They are not standard SAE size O rings They are available in the O ring field service ki
35. should be replaced Result The meter indicates a very low resistance which does not increase The capacitor is faulty and should be replaced Probable causes of capacitor failure Normal end of life failure Overheated due to light fixture heat or high ambienttemperature Incorrect capacitor voltage rating Capacitor becomes loose in ballast box AL8000HT Light Tower Part No 116478 September2008 Section 4 Repair Procedures REV 7 3 Fuel Tank How to Remove a Fuel Tank 1 Open both cabinet doors 2 Remove the fuel filler cap from the tank Using an approved hand operated pump drain the fuel tank into a container of suitable capacity Refer to Section 2 Specifications ADANGER Explosion and fire hazard Engine fuels are combustible Perform this procedure in an open well ventilated area away from heaters sparks flames and lighted tobacco Always have an approved fire extinguisher within easy reach ADANGER Explosion and fire hazard When transferring fuel connect grounding wire between the machine and pump or container Be sure to only use a hand operated pump suitable for use with diesel fuel Note If your machine is equipped with dual fuel tanks repeat this procedure beginning with step 2 for the other fuel tank 3 Tag disconnect and plug the fuel hoses from the fuel tank Clean up any fuel that may have spilled TEREX CHASSIS COMPONENTS Models
36. turned off for at least 15 minutes before servicing the machine Use a voltmeter to confirm there is no residual voltage in the capacitors Note This procedure is only for the capacitors which are attached to the lighting ballasts To test a generator capacitor see 6 1 How to Check a Generator Capacitor 1 Open both cabinet doors and locate the light ballast boxes on each side of the machine 2 Choose a ballast box Tag and disconnect the wire harness connector from the ballast box Note If the ballast capacitor to be tested is located under another ballast box the top ballast box will need to be removed first 4 Usinganinsulated conductor or a screwdriver with an insulated handle discharge the capacitor by shorting across the capacitor terminals ADANGER Electrocution hazard Exposure to high voltage electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Use extreme caution when working with high voltage electrical components 5 With an ohmmeter set to its highest resistance scale connect the ohmmeter leads to the capacitor terminals and observe the reading on the meter Then reverse the connections and observe the reading on the meter Result The meter indicates a resistance which then gradually decreases The capacitor is working Result The meter indicates a very high resistance which does not decrease The capacitor is faulty and
37. without fuel containment option 4 Supportthe fuel tank support weldment at each end using lifting jacks and blocks Do not apply any lifting pressure Do not directly support the fuel tank Component damage hazard The fuel tank is plastic and may become damaged if the lifting jacks are in direct contact with the plastic tank 5 Remove the fasteners securing the fuel tank support weldment to the chassis 6 Carefully lower the fuel tank out of the chassis and remove it from the machine Component damage hazard The fuel tank is plastic and may become damaged if allowed to fall Note It may be necessary to lower the outriggers to the ground and raise the machine using the outriggers to obtain adequate clearance to completely remove the fuel tank from the machine Note Clean the fuel tank and inspect for cracks and other damage before installing it onto the machine PartNo 116478 AL8000HT Light Tower 4 21 TEREX CHASSISCOMPONENTS Models with fuel containment option 4 Support the fuel tank containment weldment at each end using lifting jacks and blocks Do not apply any lifting pressure Component damage hazard The fuel tank is plastic and may become damaged if the lifting jacks are in direct contact with the plastic tank 5 Remove the fasteners securing the fuel tank containment weldment to the chassis 6 Carefully lower the fuel tank out of the chassis and remove it from the machine Remove the fuel
38. 0c Wada 0L MM SL MLN 9 ZL Ld3O3M N39 3ZIS ayoo V08 0 V09 SL VOS MA ZL 3ZIS Part No 116478 6 10 September2008 Section 6 Schematics TEREX AC Electrical Schematic REV Autostart Models with 4 Lights RECEPTACLES RED BLACK 6 MTW 8 EPDM 8 KW 10 4 SOW 12 KW 15 KW 10 EPDM 20 KW n o a 9 N wn x Ty Q uj zx lt 75 m F gt Ort x u BLACK TO BALLAST BOX 1 BLACK BALLAST BOX 2 BLACK TO BALLAST BOX 3 BLACK TO BALLAST BOX 4 40 3GISNI GNNOYD OL NERS WOIVGNG 40 3qISNI 931 WELTEN OL 3qISNI 931 OL NO1V83N39 40 3GISNI 931 AOZT OL DVIG T4 XO8 1SVTIV8 WOW Xx 3395 1SVTIV8 2 TES 1SVTIV8 uH LT STH SWIC lt 5 lt lt Solos rile ae ERS b 1SVTIV8 WOW X ETH 1 5 5 gt COIL CORD 5
39. 1 1800 rpm Cold cranking 500 centrifugal mechanical Reserve capacity 25A rate 105 minutes 0 0057 to 0 0072 in 0 145 to 0 185 mm Alternator Output 40A 12V DC Capacity 3 27 quarts 3 1 liters Lubrication system Oil pressure 28 to 64 psi 1 93 to 4 41 bar Oil capacity 5 4 quarts including filter 5 1 liters Oil pressure switch 7 psi engine shutoff pressure Cil viscosity requirements Units ship with 10W 30 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine 1 4 to 3 8 inch 7 to 9 mm Fan belt deflection Continuous improvement of our products is a Terex policy Product specifications are subject to change without notice AL8000HT Light Tower Part No 116478 September2008 REV A Section 2 Specifications Kubota V1505 E Engine Displacement Number of cylinders Bore and stroke Horsepower continuous Firing order Compression ratio Compression pressure Engine speed Governor Valve clearance cold Engine coolant 91 41 cu in 1 5 liters 4 3 07 x 3 09 inches 78 x 78 4 mm 17 9 Q 1800 rpm 13 4 kW 1 3 4 2 22 1 412 to 469 psi 28 4 to 32 3 bar 1800 rpm centrifugal mechanical 0 0057 to 0 0072 in 0 145 to 0 185 mm Capacity 4 23 quarts 4 liters Lubrication system Oil pressure 28 to 64 psi 1 93 to 4 41 ba
40. CHECKLIST D PROCEDURES September 2008 Section 3 Scheduled Maintenance Procedures REVA D 6 D 7 Perform Engine Maintenance Note Engine specifications require that this procedure be performed every 1500 hours Required maintenance procedures and additional engine information is available in the Isuzu 4LE1 Diesel Engine Instruction Manual Isuzu part number IDE 6033 OR the Kubota D 1105 and V 1505 Operator s Manual Kubota part number 16683 89169 Isuzu 4LE1 Diesel Engine Instruction Manual Terex part number 116133 Kubota D 1105 and V 1505 Operator s Manual Terex part number 893020 Perform Generator Maintenance Note Generator specifications require that this procedure be performed every 1500 hours or annually whichever comes first Required maintenance procedures and additional generator information is available in the Leroy Somer LSA 37 Installation and Maintenance Manual Leroy Somer part number 3664EN 09 2005 B OR the Marathon Installation Operation and Maintenance Manual Marathon part number GPNO12 OR the Newage Installation Service and Maintenance Manual Newage part number BCH 018 Leroy Somer LSA 37 Installation and Maintenance Manual Terex part number 116118 Marathon Installation Operation and Maintenance Manual Terex part number 116188 Newage Installation Service and Maintenance Manual Terex part number 830001 PartNo 116478 AL8000HT Light Tower 3 25 TEREX CHECKLIST D P
41. EX TABLE OF CONTENTS 5 2 GloWP OgS u uku 4 14 5 3 Coolant Temperature and Oil Pressure Switches 4 14 Section 4 Rev Repair Procedures continued A Generator 6 GSNGRAION eee E 4 15 A Chassis Components 7 1 GrOUNA Controls 00000000 4 19 4 2 nt Op eniti bates 4 20 TS 4 21 8 1 Function Manifold Components sess 4 23 82 Valve Adjustments Function Manifold 4 24 Section5 Rev Troubleshooting Pm 5 1 A Troubleshooting 5 2 LightFixture Troubleshooting 444 5 5 Section 6 Rev Schematics A gore Proton 6 1 A Electrical Symbols Legend 6 2 A Hydraulic Symbols Legend 6 3 A Electrical Schematic Machine 6 4 A DC Electrical Schematic Control Box and Engine Isuzu Models 6 5 A DC Electrical Schematic Control Box and Engine Kubota Models 6 6 A DC Electrical Schematic Control
42. GR d e RETRACT BLK WH e EXTEND BLK i e e 2 Ld RED BLK d RED G 9 ie C September 2008 REVA TOWER ROTATE LEFT VALVE COIL TOWER ROTATE RIGHT VALVE COIL LIGHT BAR DOWN VALVE COIL LIGHT BAR UP VALVE COIL TOWER RETRACT VALVE COIL TOWER EXTEND VALVE COIL TOWER DOWN VALVE COIL TOWER UP VALVE COIL STOWED LIMIT SWITCH PUMP MOTOR CONTACTOR LIFT PUMP MOTOR AL8000HT Light Tower Part No 116478 Isuzu Models TEREX DC Electrical Schematic Control Box and Engine Section 6 Schematics September2008 REV LZ89LL LYYd SSANYVH SL89LL H38INQN LYYd SSANYVH oN 3univiuiadwal NV1009 HOIH a L 6600000000000 3unss3ud 18 0HO N di Q 9 Q Q Q Q O O O O 0 faf of l ol of 6 8 4 9 s v z GION31OS x 4 us z A 1545 NOLING AZ u 1v3H3 d 5 H 19 13 1 LHSM E 1 TD BOT SLNANOdWOD 3NIONH AL8000HT Light Tower PartNo
43. L8000HT Light Tower 3 7 TEREX CHECKLIST PROCEDURES A 2 Perform Pre operation Inspection Note Terex specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing a pre operation inspection is essential to safe machine operation The pre operation inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Complete information on how to perform this procedure is available in the appropriate Operator s Manual Refer to the Operator s Manual on your machine Section Scheduled Maintenance Procedures September 2008 REVA A 3 Perform Function Tests Note Terex specifications require that this procedure be performed every 8 hours or daily whichever comes first Completing the function tests is essential to safe machine operation Function tests are designed to discover any malfunctions before the machine is put into service A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Complete information on how to perform this procedure is available in the appropriate Operator s Manual Refer to the Operator s Manual on your ma
44. Note When installing a rotation motor the gear backlash will need to be adjusted See How to Adjust the Tower Rotation Gear Backlash Rotation Gear Backlash The rotation motor mounting fasteners are located in slotted holes to allow the adjustment of gear backlash between the motor pinion gear and the rotation bearing ring gear Proper backlash adjustment is critical to safe machine operation and component service life An improper backlash adjustment could decrease component service life and may result in component damage Note Perform this procedure with the tower in the stowed position and the transport lock pin installed 1 Loosen the tower rotation motor mounting fasteners Do not remove them 2 Push the rotation motor towards the rotation bearing as far as possible this will push the pinion gear into the rotation bearing ring gear Loosen the lock nut on the adjustment bolt 4 Adjust the lock nuts until there is approximately 1 16 inch 1 5 mm gap between the end of the bolt and the rotation motor case Tighten the lock nuts of the adjustment bolt 5 Rotate the rotation motor away from the bearing until it contacts the adjustment bolt Torque the rotation motor fasteners to specification Refer to Section 2 Specifications 6 Rotate the tower through full range of motion Check for tight spots and binding Readjust if necessary AL8000HT Light Tower PartNo 116478 TEREX M Kubota D1105 E V1505 E Eng
45. ORE TOUCHING EXTRA PRECAUTIONS WHEN TROUBLESHOOTING ELECTRICAL PROBLEMS A Only use a voltmeter with two well insu lated pin probes rated for 600 volts B Treat all conductors as potentially hot C Proceed through circuits systematically operating only one section at a time D Before disconnecting ballast turn off circuit breaker and wait 30 seconds for capacitor to discharge E If all the lights are out and all the ballasts are receiving power suspect burned out power cable PartNo 116478 AL8000HT Light Tower 5 5 Section 5 Troubleshooting September2008 TEREX REV A This page intentionally left blank 5 6 AL8000HT Light Tower PartNo 116478 September2008 REV Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Section 6 Schematics TEREX Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawing
46. ROCEDURES D 8 Perform Tongue Jack and Outrigger Jack Maintenance Note Tongue and outrigger jack specifications require that this procedure be performed annually Required maintenance procedures and additional hitch information is available in the Cequent Tongue Jack Use Manual Cequent part number F3282ML Cequent Tongue Jack Use Manual Terex part number 150140 Section 3 Scheduled Maintenance Procedures September 2008 REVA D 9 Perform Axle Maintenance Note Axle specifications require that this procedure be performed annually or every 12 000 miles which ever comes first Proper axle maintenance following the axle manufacturer s maintenance schedule is essential to good axle performance and service life Failure to perform the maintenance procedures can lead to poor axle performance and component damage Required maintenance procedures and additional axle information is available in the Axis Axle Operator Maintenance Manualincluded with your machine Axis Axle Operator Maintenance Manual Terex part number 116117 AL8000HT Light Tower PartNo 116478 September2008 Section 3 Scheduled Maintenance Procedures TEREX Checklist E Procedures REVA E 1 Test or Replace the Hydraulic Oil Note Terex requires that this procedure be performed every 2000 hours or every two years whichever comes first Replacement or testing of the hydraulic oil is essential for good machin
47. TEREX AL8000HT First Edition Rev A Part No 116478 September 2008 TEREX Introduction Important Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine before attempting any maintenance procedure Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting equipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized Terex dealer service center Technical Publications Terex has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a Terex policy Therefore product specifications are subject to change without notice Readers are encouraged to notify Terex of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us Internet www genielift com e mail techpub genieind com September 2008 Copyright 2008 by Terex Terex Rock Hill 590 Huey Road Rock Hill SC 29730 116478 Rev A September 2008 First Edition First Printing 6 Printed on recycled paper Printed in U S A li AL8000HT Light Tower PartNo 116478 September2008 TEREX How to Read Your Serial Number
48. and Engine with Autostart Option 6 7 A AC Electrical Schematic Standard Models with 4 Lights 6 8 A AC Electrical Schematic Standard Models with 6 Lights 6 9 A AC Electrical Schematic Standard Models with 8 Lights 6 10 A AC Electrical Schematic Autostart Models with 4 Lights 6 11 A AC Electrical Schematic Autostart Models with 6 Lights 6 12 A AC Electrical Schematic Autostart Models with 8 Lights 6 13 A Receptacle Wiring 6 14 Hydraulic Schetriatie 6 15 PartNo 116478 AL8000HT Light Tower ix TEREX September2008 Parts Stocking List Required Parts The following parts are required to perform maintenance procedures as outlined in the TEREX AL8000HT Parts and Service Manual Description Part No Kubota Models Oil Filter 866050 Air Filter IDEE 866127 Fuel Filtet u a enira uu n ss 839200 se 839209 Isuzu Models OILEIIGE uyu uu us ay as 868075 A EMIOI 834460 868137 Q 868067 Manuals TEREX Corporation offers the following manuals for these models
49. art No 116478 September2008 Observe and Obey Repair procedures shall be completed by person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine sure that all necessary tools and parts available and ready for use Use only Terex approved replacement parts Read each procedure completely adhere to the instructions Attempting shortcuts may produce hazardous conditions Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked on firm level surface Key switch in the off position manual start models Toggle switch in the off position automatic start models Mast the stowed position Light switches in the off position Wheels chocked Section 4 Repair Procedures TEREX Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be c
50. ba agrees 2 1 Performance Specifications 2 1 Hydraulic Specifications 040 1 011000 ananena iiaa enne 2 2 Hydraulic Component Specifications 2 2 Manifold Component Specifications ssssssssseseeeeeennnns 2 3 Kubota D1105 E rrt eren tette pneter n REIR RR d nn A 2 4 Kubota 1505 ENGO sp 2 5 Fr ENGINE 2 6 Generator Specifications pisiasi ieai tiit tta t ve ive x ud 2 7 Hydraulic Hose and Fitting Torque Specifications 2 8 SAE and Metric Fasteners Torque Charts 2 9 Genset Torque Specifications 2 10 Section3 Rev Scheduled Maintenance Procedures oy E 3 1 Pre delivery Preparation 3 3 Maintenance Inspection Report corii ctt uuu ukawa cte 3 5 A Checklist A Procedures A 1 Inspect the Manuals and Decals 3 7 A 2 Perform Pre operation Inspection uuu 3 8 A 3 Perform Function Tests cer ree E ere tru oC ease 3 8 vi AL8000HT Light Tower Part No 116478 September2008 TEREX
51. ballast name plate data should agree with the line lamp used If not replace the ballast down time insufficient to cool 12 Lamp starts slowly arc does a Defective lamp a Lamp may glow for an extended not strike when switch is first period of time Replace after turned on checking voltage and ballast 13 Circuit breaker trips on lamp a Short circuit or ground a Check wiring against diagram inspect for shorts or ground Fix as needed 14 Lamp light output low a Normal lamp depreciation b Dirty lamp or fixture b Clean lamp and fixture c Defective ballast c Interchange ballast plugs If lamp starts replace ballast Check for swollen capacitors charred wiring core and coil or other signs of excessive heat d Check line voltage at ballast input Voltage should be within 1096 of rating when operating at normal load Check wiring connections for voltage loss Check socket contact point e Improper ballast e Check ballast name plate against lamp data 15 Lamp colors different a Normal lamp depreciation a Replace lamp b Dirty lamp or fixture b Clean lamp and fixture c Check data on lamps and replace as needed 16 Arc tube discolored or swollen a Over voltage from power supply a Check voltage at ballast for current or voltage surges for shorted capacitors and replace as needed b Improper ballast b Check ballast name plate against lamp data 17 Short lamp life a Lamp damaged a Check for outer bulb crac
52. chine 3 8 AL8000HT Light Tower PartNo 116478 TEREX CHECKLIST PROCEDURES September2008 Section 3 Scheduled Maintenance Procedures REV A 4 A 5 Perform Engine Maintenance Isuzu Models Note Engine specifications require that this procedure be performed every 8 hours or daily whichever comes first Required maintenance procedures and additional engine information is available in the Isuzu 4LE1 Diesel Engine Instruction Manual Isuzu part number IDE 6033 Isuzu 4LE1 Diesel Engine Instruction Manual Terex part number 116133 Perform Generator Maintenance Note Generator specifications require that this procedure be performed every 8 hours or daily whichever comes first Required maintenance procedures and additional generator information is available in the Leroy Somer LSA 37 Installation and Maintenance Manual Leroy Somer part number 3664EN 09 2005 B OR the Marathon Installation Operation and Maintenance Manual Marathon part number GPNO12 OR the Newage Installation Service and Maintenance Manual Newage part number BCH 018 Leroy Somer LSA 37 Installation and Maintenance Manual Terex part number 116118 Marathon Installation Operation and Maintenance Manual Terex part number 116188 Newage Installation Service and Maintenance Manual Terex part number 830001 PartNo 116478 AL8000HT Light Tower 3 9 TEREX CHECKLIST PROCEDURES A 6 Perform Axle Maintenance No
53. clamp fasteners and clamps from the underside of the cable track on the side of tower tube number 1 4 Place blocks between the cable track tube and the lower cable track Secure the cable track together PartNo 116478 AL8000HT Light Tower 4 7 TEREX TOWERCOMPONENTS 5 Attach a suitable lifting device to the cable track Carefully remove the cable track from the tower and rest it on top of the cabinet Component damage hazard Cables and hoses can become damaged if they are kinked or pinched 6 Place a block under the tower lift cylinder for support 7 Remove the pin retaining fasteners from the tower lift cylinder rod end pivot pin 8 Use a soft metal drift to remove the pin Rest the tower lift cylinder on the block 9 Tag disconnect and plug the tower extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 10 Position the forks from a forklift into the forklift pockets located under the tower Secure the tower to the forks 11 Remove the transport lock pin from the tower near the tower rest pad 12 Remove the pin retaining fasteners from the tower pivot pin at the tower rotation riser 13 Use a soft metal drift to remove the tower pivot pin Carefully remove the tower assembly
54. d every 250 hours or quarterly whichever comes first Required maintenance procedures and additional engine information is available in the Isuzu 4LE1 Diesel Engine Instruction Manual Isuzu part number IDE 6033 Isuzu 4LE1 Diesel Engine Instruction Manual Terex part number 116133 Section Scheduled Maintenance Procedures September 2008 REVA B 6 Perform Generator Maintenance Note Generator specifications require that this procedure be performed every 250 hours or quarterly whichever comes first Required maintenance procedures and additional generator information is available in the Leroy Somer LSA 37 Installation and Maintenance Manual Leroy Somer part number 3664EN 09 2005 B OR the Marathon Installation Operation and Maintenance Manual Marathon part number GPNO12 OR the Newage Installation Service and Maintenance Manual Newage part number BCH 018 Leroy Somer LSA 37 Installation and Maintenance Manual Terex part number 116118 Marathon Installation Operation and Maintenance Manual Terex part number 116188 Newage Installation Service and Maintenance Manual Terex part number 830001 AL8000HT Light Tower Part No 116478 TEREX CHECKLIST PROCEDURES Perform Engine Maintenance September2008 Section 3 Scheduled Maintenance Procedures REV A B 7 B 8 Perform Hitch Coupler Maintenance Kubota Models Note Hitch specifications require that this procedure be pe
55. death or serious injury Remove all rings watches and other jewelry Use extreme caution when working with high voltage electrical components 14 Loosen the wiring clamp located on the back of the capacitor compartment of the generator Pull the wiring out of the terminal box through the wiring clamp 15 Use a lifting jack or similar device to support the rear of the engine Do not apply any lifting pressure 16 Remove the generator fan screens from both sides of the generator 17 Remove the fasteners securing the generator to the engine flywheel 18 Remove the fasteners securing the generator to the chassis 19 Attach a lifting strap from an overhead crane or other suitable device to both lifting eyes on the generator Support the generator Do not apply any lifting pressure 20 Remove the fasteners securing the generator to the engine bellhousing 21 Remove the generator from the machine Crushing hazard The generator ACAUTION may become unbalanced and fall if not properly supported when removed from the machine Section 4 Repair Procedures TEREX GENERATOR How to Remove the Generator Newage Generator Models ADANGER Electrocution hazard Exposure to high voltage electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Turn off all power when not needed for testing Use extreme caution when working with high voltage electrical com
56. e performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Note Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Open both cabinet covers 2 Tag and disconnect the battery cables from the battery AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry 3 Tag disconnect and plug the hydraulic hoses from the power unit Cap the fittings AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Tag and disconnect the electrical wiring and cables from the power unit 5 Support and secure the power unit to a suitable lifting device
57. e the cylinder from the machine Component damage hazard Cables and hoses can be damaged if the cylinder is dragged across them AL8000HT Light Tower PartNo 116478 September2008 REV A 3 4 Tower Extension Cylinder How to Remove the Tower Extension Cylinder The tower extension cylinder extends and retracts the tower assembly The cylinder is used to extend and retract the number 2 tower tube while cables are used to extend and retract the number 3 tower tube The tower extension cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the tower extension cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Attach a lifting strap from an overhead crane to the tower extension cylinder Section 4 Repair Procedures TEREX TOWER COMPONENTS 3 Remove the external snap rings from the tower extension cylinder rod end pivot pin Use a soft metal drift to remove the pin 4 Remove
58. earing and gear will resultincomponent damage 1 Lowerallfour outriggers to the ground and level the machine 2 Remove the tower transport lock pin Raise the tower to a vertical position 4 Locate the grease fitting on the inner race of the bearing 5 Pump grease into the tower rotation bearing Rotate the tower in increments of 4 to 5 inches 10 to 13 cm at a time and repeat this step until the entire bearing has been greased 6 Removeretaining fasteners from the the pinion gear guard Remove the guard 7 Apply grease to each tooth of the pinion gear 3 12 AL8000HT Light Tower PartNo 116478 TEREX CHECKLIST PROCEDURES September2008 Section 3 Scheduled Maintenance Procedures REV A 11 A 12 Perform Engine Maintenance Kubota Models Note Engine specifications require that this procedure be performed every 100 hours Required maintenance procedures and additional engine information is available in the Kubota D 1105 and V 1505 Operator s Manual Kubota part number 16683 89169 Kubota D 1105 and V 1505 Operator s Manual Terex part number 893020 Perform Engine Maintenance Kubota Models Note Engine specifications require that this procedure be performed every 200 hours Required maintenance procedures and additional engine information is available in the Kubota D 1105 and V 1505 Operator s Manual Kubota part number 16683 89169 Kubota D 1105 and V 1505 Operator s Manual Terex part
59. ection 3 Scheduled Maintenance Procedures TEREX CHECKLIST A PROCEDURES A 9 Perform Hitch Maintenance Note Hitch specifications require that this procedure be performed weekly Required maintenance procedures and additional hitch information is available in the Fulton Coupler User Manual Fulton part number F1937 Fulton Coupler User Manual Terex part number 150139 Isuzu 4LE1 Diesel Engine Instruction Manual Terex part number 116133 Kubota D 1105 and V 1505 Operator s Manual Terex part number 893020 Part No 116478 AL8000HT Light Tower 3 11 Section 3 Scheduled Maintenance Procedures September2008 TEREX CHECKLIST PROCEDURES REV A 10 8 Rotate the tower to transfer the grease from the Grease the Turntable Rotation pinion gear to the teeth of the rotation bearing 9 Repeat steps 5 and 6 until all gear teeth are Bearing and Rotate Gear 10 Install the pinion gear guard and securely tighten the retaining fasteners Do not overtighten Note Terex specifications require that this procedure be performed every 100 hours of Grease Specification operation Perform this procedure more often if dusty conditions exist Chevron Ultra duty grease EP NLGI 2 lithium based or equivalent Frequent application of lubrication to the turntable rotation bearing and rotate gear is essential to good machine performance and service life Continued use of an improperly greased b
60. en turned back on while they are still warm they may not light up again for 10 to 20 minutes AL8000HT Light Tower Part No 116478 September2008 Section 4 Repair Procedures REV Time Line Voltage Initial ignition 415V AC 30 seconds 412V AC 1 minute 413V AC 2 minutes 416V AC 5 minutes 246V AC 10 minutes 251V AC Note If the voltage reading remains high during warm up check for loose or broken wire connections OR the lamp may be faulty Note The voltage readings provided in the chart are averages voltage on your machine may vary TEREX LIGHTING How to Check the Open Circuit Voltage Correct line voltage at the lamp socket is essential for proper operation of the lighting system Electrocution hazard Exposure to high voltage electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Turn off allpower when not needed for testing Use extreme caution when working with high voltage electrical components 1 Turn offallmachine power 2 Locate the electrical cable of the lamp to be tested Disconnect the cable from the junction box attached to the light bar 3 Seta voltmeter to read 0 to 750V AC Insert the leads of the voltmeter into pins A and B of the electrical connector socket at the junction box 9 6 VS 4 Start the engine 5 Turn the appropriate circuit breaker light switc
61. er 5 Install the new filter and tighten it securely by hand Clean up any oil that may have spilled 6 Pull out the red Emergency Stop button if equipped to the on position located on the back panel of the light tower cabinet 7 Activate any tower function and inspect the filter and related components to be sure that there are no leaks 8 Usea permanent ink marker to write the date and number of hours from the hour meter on the oil filter PartNo 116478 AL8000HT Light Tower 3 23 TEREX CHECKLIST D PROCEDURES D 4 Perform Engine Maintenance Isuzu Models Note Engine specifications require that this procedure be performed every 1000 hours or annually whichever comes first Required maintenance procedures and additional engine information is available in the Isuzu 4LE1 Diesel Engine Instruction Manual Isuzu part number IDE 6033 Isuzu 4LE1 Diesel Engine Instruction Manual Terex part number 116133 Section Scheduled Maintenance Procedures September 2008 REVA D 5 Perform Engine Maintenance Isuzu Models Note Engine specifications require that this procedure be performed every 1250 hours Required maintenance procedures and additional engine information is available in the Isuzu 4LE1 Diesel Engine Instruction Manual Isuzu part number IDE 6033 Isuzu 4LE1 Diesel Engine Instruction Manual Terex part number 116133 AL8000HT Light Tower PartNo 116478 TEREX
62. h to the ON position and observe the reading on the voltmeter Refer to the following chart Open Circuit Voltage 375V AC to 465V AC Specification Note If there is no reading on the meter Repair or replace the capacitor ballast or wiring PartNo 116478 AL8000HT Light Tower TEREX Light Bar Components 2 1 Light Bar How to Remove the Light Bar Assembly Section 4 Repair Procedures September2008 REV Remove the pin retaining fasteners from light bar lift cylinder barrel end pivot pin D Place rod through the pin and twist to remove the pin Remove the pin retaining fasteners from the light bar pivot pin B and the light bar lever pivot pin A Place a rod through the pins and twist to remove the pins Note Perform this procedure with the tower in the pum stowed position Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the light bar cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Tagand disconnect the lamp electrical cables from each junc
63. heck a Generator Generator How to Remove the Generator Capacitor Cover Leroy Somer Models ADANGER Electrocution hazard Exposure to high voltage electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Turn off all power when not needed for testing Use extreme caution when working with high voltage electrical components Note Be sure the engine has been turned off for at least 15 minutes before servicing the machine Use a voltmeter to confirm there is no residual voltage in the capacitors 1 Loosen but do not remove the fasteners securing the capacitor cover to the top of the generator ACAUTION Burn hazard Contact with hot engine components may cause severe burns Use caution when working around a hot engine 2 Pull the cover off the top of the generator to access the wire harness where it connects to the generator 3 Tag and disconnect the wires at the top of the generator Remove the cover Capacitor Leroy Somer Models ADANGER Electrocution hazard Exposure to high voltage electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Turn off all power when not needed for testing Use extreme caution when working with high voltage electrical components ADANGER Electrocution hazard Attempting to service the machine before the capacitors are fully discharged will resul
64. hine Models with Newage generators 11 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 12 Remove the fasteners securing the terminal box cover to the top of the generator Remove the cover Burn hazard Contact with hot ACAUTION engine components may cause severe burns Use caution when working around a hot engine 13 Tag and disconnect the black white and green wires that enter the terminal box from the generator ADANGER Electrocution hazard Exposure to high voltage electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Use extreme caution when working with high voltage electrical componenis 14 Loosen the wiring clamp located on the back of the capacitor compartment of the generator Pull the wiring out of the terminal box through the wiring clamp 15 Use a lifting jack or similar device to support the rear of the engine Do not apply any lifting pressure Section 4 Repair Procedures September 2008 REVA 16 Remove the generator fan screens from both sides of the generator Note The generator fan screens cover the generator fan blades and are located between the generator and the engine bellhousing 17 Remove the fasteners securing the generator to the engine flywheel 18 Remove
65. ht mounting fasteners and set the domelight aside 6 Locate the wiring for the limit switch located at the transport lock pin Tag and disconnect the limit switch wiring from inside the engine compartment 7 Remove the limit switch mounting fasteners and set the switch aside 8 Remove the tower rest pad weldment fasteners Remove the rest pad from the cabinet 9 Support the cabinet top with a suitable lifting device 10 Remove all fasteners securing the cabinet top to the cabinet end panels Carefully remove the cabinet top from the machine Crushing hazard The cabinet top ACAUTION may become unbalanced and fall if not properly supported when removed from the machine Models with Marathon generators 11 Disconnect the battery from the machine AWARNING Electrocution hazard Contact with hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 12 Remove the fasteners securing the terminal box cover to the top of the generator Remove the cover Burn hazard Contact with hot ACAUTION engine components may cause severe burns Use caution when working around a hot engine AL8000HT Light Tower Part No 116478 September2008 REV A 13 Tag and disconnect the black white and green wires that enter the terminal box from the generator Electrocution hazard Exposure to high voltage electrical wires or electrical current will result in
66. ike battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas N are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity i Be sure any forklift overhead crane or Be sure n fasteners intended for one N time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time Be sure to properly dispose of old oil or 2 other fluids Use an approved container Please be environmentally safe Be sure that your workshop or work area is properly ventilated well lit NM PartNo 116478 AL8000HT Light Tower TEREX September2008 Table of Contents Introduction Imponan Mionna EUR Howto Read Your Serial ili Parts Stocking erii x Howto Order a iu kuna e xi Service Parts Fax Order FOtfifl Section 1 Safety Rules Gerieral Safely ass pue iv Section2 Rev Specifications A Machine Specifications oec i etre uyantaq
67. in Pull the cable end out of the pivot pin 4 8 AL8000HT Light Tower Part No 116478 September2008 REV A 6 Remove the external snap rings from both the tower extension cylinder rod end pivot pin and the extend cable pivot pin Use a soft metal drift to remove the pins 7 Attach a lifting strap from an overhead crane to the tower extension cylinder 8 Remove the external snap rings from the tower extension cylinder barrel end pivot pin Use a soft metal drift to remove the pin Carefully remove the cylinder from the machine Crushing hazard The tower AWARNING extension cylinder could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane 9 Remove the cable retaining nut from the retract cable located on the bottom of tower tube number 1 at the extension end of the tower 10 Label and remove the wear pads from the extension end of the number 1 tower tube 11 Attach a lifting strap from an overhead crane to the number 2 and 3 tower tubes Section 4 Repair Procedures TEREX TOWER COMPONENTS 12 Support and slide the number 2 and 3 tower tubes out of the number 1 tower tube and place them on a structure capable of supporting them Crushing hazard The number 2 AWARNING and 3 tower tubes could become unbalanced and fall when removed from the number 1 tube if not properly supported by the overhead crane Bodily injury hazard Cables can ACAUTION
68. ine 4 1 4 3 Timing Adjustment Complete information to perform this procedure is available in the Kubota 05 Series Workshop Manual Kubota part number 97897 02432 Kubota 05 Series Workshop Manual Terex part number 31742 4 2 Glow Plugs How to Check the Glow Plugs 1 Disconnect the wiring and buss bar from the glow plugs 2 Connectthe leads from an ohmmeter between each glow plug terminal and ground Result The resistance should be approximately 10 Result The resistance is 00 or greater than 10 The glow plug is faulty Coolant Temperature and Oil Pressure Switches The engine coolant temperature switch is a normally open switch The switch contacts close at approximately 225 F 107 C If the coolant temperature rises above the switch point the switch contacts close and the engine will shut off to prevent damage The engine will not start until the temperature drops below the switch point Additionally a low collant level can cause the coolant temperature switch to not work properly Make sure that the coolant system is at the proper level The engine oil pressure switch is a normally closed switch The switch contacts open at approximately 7 0 48 bar If the oil pressure drops below the Switch point the contacts open and the engine will shut off to prevent damage PartNo 116478 AL8000HT Light Tower TEREX Isuzu 4LE1 Engine 5 1 Timing Adjustment Complete information to
69. iv AL8000HT Light Tower PartNo 116478 September2008 Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death A ADANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards 3il such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Section 1 Safety Rules TEREX SAFETY RULES Workplace Safety Be sure to keep sparks flames and W lighted tobacco away from flammable and combustible materials l
70. ker normally close with amperage A 4 pai m B s Power relay Main circuit breaker Fuel or RPM J solenoid CR4 f Control relay contact Light switch normally open Coil 6 2 AL8000HT Light Tower Part No 116478 September2008 Section 6 Schematics TEREX Hydraulic Symbols Legend REV 25 lt 1 7 2525 T Q 0 89 mm 1 Orifice with size Solenoid operated 3 position Filter with 4 way directional valve bypass valve relief setting Check valve r 200 psi gt 13 8 bar C 1 Mon EN fixed displacement _ Relief valve Priority with pressure setting flow regulator valve E web mde ees Pump prime mover x ea i 1 engine or motor i gt Ul E I 2 2 4 Cross relief valve fp Counterbalance valve Double acting with pressure and pilot ratio cylinder PartNo 116478 AL8000HT Light Tower 6 3 TEREX Section 6 Schematics Electrical Schematic Machine Functions FUSE 30A LEFT WH rue RIGHT I WH BLK DOWN GR BLK LIGHT
71. ks cracks where lamp meets base and for broken arc tube or loose metal parts Replace as needed b Check ballast name plate against lamp data 18 Lamp flickers or goes out a Check ballast name plate against intermittent or cycling lamp data b New lamp b Under certain conditions new lamps may cycle Usually after 3 tries to start at 30 to 60 second intervals lamp will stabilize and operate normal 5 4 AL8000HT Light Tower PartNo 116478 September 2008 Section 5 Troubleshooting TEREX REVA TROUBLESHOOTING TROUBLE POSSIBLE CAUSE REMEDY 18 Lamp flickers or goes out intermittent or cycling d Defective lamp d Replace lamp e High spike ballast e Ballast produces high spike current Measure with oscilloscope Replace ballast as required IF YOU FEEL AN ELECTRIC SHOCK ANY TIME WHILE OPERATING THIS UNIT SHUT IT DOWN IMMEDIATELY HAVE THEUNITINSPECTED BY ATRAINED ELECTRICIAN THIS ENGINE GENERATOR SET IS FACTORY INSTALLED TESTED AND SET FOR FIELD OPERATION ANY DAMAGETO THE ENGINE OR GENERATOR UNITS OCCURRING AFTER ADJUSTMENTS ARE MADE IN THEFIELD BY UNAUTHORIZED PERSONNEL WILL NOT BE COVERED BY YOURMANUFACTURER S WARRANTY AND WILL ALSO VOID THE MANUFACTURER S WARRANTY ON THIS PARTICULAR UNIT IF YOU CAN NOT REACH YOURLO CAL DEALER CONTACT THE FACTORY SERVICEMANAGER TOLL FREE AT 1 800 433 3026 Light Fixture Troubleshooting DO NOT OPENFIXTURES WHILE LIGHT CIRCUIT BREAKER IS ON ALLOW LAMP TO COOL BEF
72. l the machine 2 Remove the tower transport lock pin 3 Raise the tower to a vertical position 4 Checkto be sure that each tower mounting bolt is torqued in sequence to specification Refer to Section 2 Specifications Tongue Bolt torque sequence AL8000HT Light Tower PartNo 116478 September2008 REV 5 Check to be sure that each bearing mounting bolt under the tower support is torqued in sequence to specification Refer to Section 2 Specifications Tongue Bolt torque sequence Section 3 Scheduled Maintenance Procedures TEREX CHECKLIST D PROCEDURES D 3 Replace the Hydraulic Return Filter Note Terex requires that this procedure be performed every 1000 hours or annually whichever comes first Replacement of the hydraulic return filter is essential for good machine performance and service life A dirty or clogged filter may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require that the filter be replaced more often Bodily injury hazard Beware of hot ACAUTION oil Contact with hot oil may cause severe burns 1 Openthe road side cabinet cover and locate the hydraulic return filter next to the power unit 2 Place a suitable container under the hydraulic filter 3 Clean the area around the filter Remove the filter with an oil filter wrench 4 Apply a thin layer of fresh oil to the gasket of the new oil filt
73. maintenance Isuzu models Perform every 1250 hours D 5 Engine maintenance Isuzu models Perform every 1500 hours D 6 Engine maintenance D 7 Generator maintenance Perform annually D 8 Tongue and outrigger jack maintenance Perform every 12 000 miles D 9 Axle maintenance Checklist E Rev A Y R E 1 Test or replace hydraulic oil Perform every 3000 hours E 2 Engine maintenance Kubota models Perform every 2 years E 3 Engine maintenance Kubota models Perform every 4500 hours E 4 Generator maintenance Perform every 15 000 hours E 5 Generator maintenance Comments September 2008 AL8000HT Light Tower Part No 116478 September2008 Section 3 Scheduled Maintenance Procedures TEREX Checklist A Procedures REVA A 1 Inspect the Manuals and Decals Note Terex specifications require that this procedure be performed daily or every 8 hours whichever comes first Maintaining the operator s and safety manuals in good condition is essential to safe machine operation Manuals are included with each machine and should be stored in the container provided in the cabinet An illegible or missing manual will not provide safety and operational information necessary for a safe operating condition In addition maintaining all of the safety and instructional decals in good condition is mandatory for safe machine operati
74. minimum of 4 years or in compliance with employer jobsite and governmental regulations and requirements 3 2 AL8000HT Light Tower Part No 116478 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual TEREX TEREX Rock Hill P O BOX 3147 Rock Hill SC 29732 USA Toll Free 800 433 3026 in U S A and Canada Copyright 2006 by TEREX Corporation TEREXGis a registered trademark of TEREX Corporation RevB Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part
75. nd pulleys C 2 Engine maintenance Perform every 6000 miles C 3 Axle maintenance Perform every 750 hours C 5 Engine maintenance Isuzu models Perform every 800 hours C 6 Engine maintenance Kubota models PartNo 116478 AL8000HT Light Tower TEREX MAINTENANCEINSPECTION REPORT Model Serial number Date Hour meter Machine owner Inspected by print Inspector signature Inspector title Inspector company Instructions Make copies of this report to use for each inspection Select the appropriate checklist s for the type of inspection to be performed Daily or 8 hours Inspection A Quarterly or 250 hours Inspection A B Semi annually or 500 hours Inspection A B C Annually or 1000 hours Inspection A B C D Two year or 2000 hours Inspection A B C D E Place a check in the appropriate box after each inspection procedure is completed Use the step by step procedures in this section to learn how to perform these inspections If any inspection receives an N tag and remove the machine from Service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Checklist D Rev A Section 3 Scheduled Maintenance Procedures D 1 Engine maintenance Kubota models D 2 Tower rotation bearing bolts D 3 Hydraulic filter D 4 Engine
76. nerator case to engine 25 ft lbs Note The following coil resistance specifications are at bell housing fasteners 34 Nm an ambient temperature of 68 F 20 C As valve coil resistance is sensitive to changes in air temperature Generator vibration 75 ft lbs the coil resistance will typically increase or decrease by isolator fasteners 102 Nm 4 for each 18 F 20 C that your air temperature increases or decreases from 68 F 20 C Flex plate to flywheel m Valve coil specifications 3 position 4 way solenoid valve 10V DC 60 schematic items B C E and G Continuous improvement of our products is a Terex policy Product specifications are subject to change without notice PartNo 116478 AL8000HT Light Tower TEREX SPECIFICATIONS Kubota D1105 E Engine Displacement Number of cylinders Bore and stroke Horsepower continuous Firing order Compression ratio Compression pressure Engine speed Governor Valve clearance cold Engine coolant Section 2 Specifications September 2008 REVA Injection system 68 53 cu in Injection pump make Bocsh MD mini 1 12 liters Injection timing 19 BTDC 3 Injection pump pressure 1991 psi 3 07 x 3 09 inches 137 bar 78 x 9 4 mrn Fuel requirement 13 6 1800 rpm For fuel requirements refer to the engine Operator s 10 1 kW Manual on your machine Ves Battery 23 1 Type 12V DC 412 to 469 psi Group 27TM 28 4 to 32 3 bar Quantity
77. odily injury hazard Cables can ACAUTION fray Always wear adequate hand protection when handling the cable Component damage hazard Cables can be damaged if they are kinked or pinched Note During removal the overhead crane strap will need to be carefully adjusted for proper balancing Section 4 Repair Procedures September 2008 REVA 3 3 Tower Lift Cylinder How to Remove the Tower Lift Cylinder The tower lift cylinder raises and lowers the tower assembly The tower lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications 1 Tag disconnect and plug the tower lift cylinder hydraulic hoses Cap the fittings on the cylinder Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Support both ends of the cylinder with a suitable device to prevent it from falling 3 Remove the pin retaining fasteners from both the rod end and barrel end pivot pins 4 Place a rod through the pins and twist to remove Guide the cylinder out the pivot end of the tower and carefully remov
78. ol zl EC n2 NI A co N oj N as E AIO o gt ool ol mi o tol Go a D e m o NN NI CO olo c aln B aJo 9 eio lt ALA r a alo Ez x 9 lt B DRY r c B DRY ML co Nm 236 46 7 13 3 I 830 1055 682 925 509 1235 36 72 e ool 2 zi WO cO O N N Aj gt eoo oo N ojo A ALN eo M Po OY On jo A o c2 lt oO ofo JO NIN Poy o On n2 On Lu Oo oe On 4 alk i rol NI alo Alo olo zi s fe DN NI RIN of ele NIN ayo o olol A amp oo Oo cd aloo el o EN el PartNo 116478 AL8000HT Light Tower 2 9
79. ompleted To re assemble perform the disassembly steps in reverse order Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous situation which if not avoided will result in death or serious injury A DANGER Indicates a potentially hazardous AWARNING situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage O Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps PartNo 116478 AL8000HT Light Tower 4 1 TEREX Lighting 1 1 Lighting How to Remove a Lamp ADANGER High voltage Exposure to electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Turn off all power when not needed for testing Use extreme caution when working with high voltage electrical components ACAUTION Burn hazard Contact with hot lamp components may cause severe burns Use caution when working aroundlamps 1 Turn off all machine power 2 Remove the light
80. on Decals alert operators and personnel to the many possible hazards associated with using this machine They also provide users with operation and maintenance information An illegible decal will fail to alert personnel of a procedure or hazard and could result in unsafe operating conditions 1 Check to make sure that the operator s and safety manuals are present and complete in the storage container inside the cabinet 2 Examine the pages of each manual to be sure that they are legible and in good condition Result The operator s manual is appropriate for the machine and all manuals are legible and in good condition Result The operator s manual is not appropriate for the machine or all manuals are not in good condition or are illegible Remove the machine from service until the manual is replaced 3 Open the operator s manual to the decals inspection section Carefully and thoroughly inspect all decals on the machine for legibility and damage Result The machine is equipped with all required decals and all decals are legible and in good condition Result The machine is not equipped with all required decals or one or more decals are illegible or in poor condition Remove the machine from service until the decals are replaced 4 Always return the manuals to the storage container after use Note Contact your authorized Terex distributor if replacement manuals or decals are needed PartNo 116478 A
81. oot hydraulic system and service as needed b Broken cable or pulley b Have a trained mechanic examine and replace as needed c Extend cylinder damaged c Inspect extend cylinder 3 Engine will not turn over a Dead battery a Check the battery voltage or loose cables b Bad starter b Check voltage at starter and replace as needed 4 Engine turns over but will a Empty fuel tank a Fill tank with 42 diesel fuel System as needed c Leaking fuel lines or a loss of prime and tighten connections d Heater elements burned out d Replace heater elements e Fuel line solenoid is not open e Replace fuel line solenoid 5 Engine runs rough a Clogged or leaking fuel system a Replace fuel lines tighten all connections inspect the pickup tube and inspect the fuel filter b Clogged exhaust system b Clear the exhaust system c Clogged air filter c Clear air filter d Clogged or stuck fuel injectors d Have a trained mechanic examine e Valve clearances are out of e Have a trained adjustment or the valve spring mechanic examine may be damaged f Defective governor or fuel pump f Have a trained mechanic examine 5 2 AL8000HT Light Tower Part No 116478 September 2008 Section 5 Troubleshooting TEREX REVA TROUBLESHOOTING TROUBLE POSSIBLE CAUSE REMEDY 6 Engine runs but produces a dense smoke b Low compression b Have a trained mechanic a inspect for broken or seized rings Inspect valve clearances and clear as needed water coolant
82. operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause component damage Electrocution hazard Contact with AWARNING hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed corroded and loose wires and for a liberal coating of dielectric grease in the harness connections Mast Chassis Trailer lighting 2 Inspect for a liberal coating of dielectric grease in the harness connections between the generator ballasts and the mast light assemblies 3 Inspectthe engine and generator area for burnt chafed corroded pinched and loose wires and and for a liberal coating of dielectric grease in the harness connections AL8000HT Light Tower PartNo 116478 September2008 REV A B 3 Inspect the Tires and Wheels including lug nut torque Note Terex requires that this procedure be performed every 250 hours or quarterly whichever comes first Maintaining the tires and wheels in good condition is essential to safe operation and good performance Tire and or wheel failure could result in a machine tip over Component damage may also result if problems are not discovered and repaired in a timely fashion AWARNING P 4ily injury hazard An over inflated tire can explode and could result in death or se
83. ot increase The capacitor is faulty and should be replaced Probable causes of capacitor failure Starting engine with circuit breakers on Shutting off engine with circuit breakers on Normalend of life failure Overheated due to light fixture heat or high ambienttemperature Incorrect capacitor voltage rating How to Remove the Generator Marathon Generator Models ADANGER Electrocution hazard Exposure to high voltage electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Turn off all power when not needed for testing Use extreme caution when working with high voltage electrical components Note Be sure the engine has been turned off for at least 15 minutes before servicing the machine Use a voltmeter to confirm there is no residual voltage in the capacitors 1 Extendallfour outriggers Lower each outrigger until they make contact with the ground 2 Raise the tower to a vertical position Do not extend the tower or raise the light bar Turn the machine Section 4 Repair Procedures September2008 REV A 3 Open each cabinet door Remove the hinge retaining fasteners from the cabinet top for each cabinet door 4 Disconnect the gas struts from each cabinet door Remove each door from the machine 5 Locate the domelight mounted to the cabinet top above the engine Remove the lens from the domelight Remove the domelig
84. perform this procedure is available in the Isuzu 4LE1 Workshop Manual Isuzu partnumber IDE 2270 Isuzu 4LE1 Workshop Manual Terex part number 116166 Section 4 Repair Procedures 5 2 Glow Plugs How to Check the Glow Plugs 1 Disconnect the wiring and buss bar from the glow plugs 2 Connect the leads from an ohmmeter between each glow plug terminal and ground Result The resistance should be approximately 1Q Result The resistance is 00 or greater than 1Q The glow plug is faulty September 2008 REV 5 3 Coolant Temperature and Oil Pressure Switches The engine coolant temperature switch is a normally open switch The switch contacts close at approximately 221 F 105 C If the coolant temperature rises above the switch point the switch contacts close and the engine will shut off to prevent damage The engine will not start until the temperature drops below the switch point Additionally a low collant level can cause the coolant temperature switch to not work properly Make sure that the coolant system is at the proper level The engine oil pressure switch is a normally closed switch The switch contacts open at approximately 14 psi 0 96 bar If the oil pressure drops below the Switch point the contacts open and the engine will shut off to prevent damage AL8000HT Light Tower PartNo 116478 TEREX Generator September 2008 Section 4 Repair Procedures REVA 6 1 How to C
85. ponents Note Be sure the engine has been turned off for at least 15 minutes before servicing the machine Use a voltmeter to confirm there is no residual voltage in the capacitors 1 Extend all four outriggers Lower each outrigger until they make contact with the ground 2 Raise the tower to a vertical position Do not extend the tower or raise the light bar Turn the machine off 3 Openeach cabinet door Remove the hinge retaining fasteners from the cabinet top for each cabinet door 4 Disconnect the gas struts from each cabinet door Remove each door from the machine 5 Locate the domelight mounted to the cabinet top above the engine Remove the lens from the domelight Remove the domelight mounting fasteners and set the domelight aside 6 Locate the wiring for the limit switch located at the transport lock pin Tag and disconnect the limit switch wiring from inside the engine compartment 7 Remove the limit switch mounting fasteners and set the switch aside 8 Remove the tower rest pad weldment fasteners Remove the rest pad from the cabinet 9 Supportthe cabinet top with a suitable lifting device PartNo 116478 AL8000HT Light Tower TEREX GENERATOR 10 Remove all fasteners securing the cabinet top to the cabinet end panels Carefully remove the cabinet top from the machine Crushing hazard The cabinettop ACAUTION may become unbalanced and fall if not properly supported when removed from the mac
86. r Oil capacity 7 08 quarts including filter 6 7 liters Oil pressure switch 7 psi engine shutoff pressure Oil viscosity requirements Units ship with 10W 30 Extreme operating temperatures may require the use of alternative engine oils For oil requirements refer to the Engine Operator Handbook on your machine TEREX SPECIFICATIONS Injection system Injection pump make Bocsh MD mini Injection timing 19 BTDC Injection pump pressure 1991 psi 137 bar Fuel requirement For fuel requirements refer to the engine Operator s Manual on your machine Battery Type 12V DC Group 271M Quantity 1 Cold cranking ampere 630 Reserve capacity 25A rate 105 minutes Alternator Output 30A 12V DC 1 4 to 3 8 inch 7to9mm Fan belt deflection PartNo 116478 AL8000HT Light Tower 2 5 TE RE Section 2 Specifications September 2008 SPECIFICATIONS REV Isuzu 4LE1 Engine Enginecoolant Displacement 133cuin Capacity 21 2 179 liters ONIS Coolant temperature switch 221 7 F Number of cylinders 4 it k E ER engine shut off temperature 105 4 Bore and stroke 3 35 x 3 78 inches 85 x 96 Injection system Horsepower continuous 31 4 1800 rpm njection pump make Bosch PFR ype 23 4kW Injection timing 16 Firing order Injection pump pressure 1920 psi Compression ratio 21 5 1 132 8 bar Engine speed 1800 Fuel requirement
87. r 116133 AL8000HT Light Tower Part No 116478 September2008 Section 3 Scheduled Maintenance Procedures REV A C 5 Perform Engine Maintenance Kubota Models Note Engine specifications require that this procedure be performed every 800 hours Required maintenance procedures and additional engine information is available in the Kubota D 1105 and V 1505 Operator s Manual Kubota part number 16683 89169 Kubota D 1105 and V 1505 Operator s Manual Terex part number 893020 TEREX CHECKLIST C PROCEDURES PartNo 116478 AL8000HT Light Tower TEREX Section 3 Scheduled Maintenance Procedures September 2008 Checklist D Procedures D 1 Perform Engine Maintenance Kubota Models Note Engine specifications require that this procedure be performed annually Required maintenance procedures and additional engine information is available in the Kubota D 1105 and V 1505 Operator s Manual Kubota part number 16683 89169 Kubota D 1105 and V 1505 Operator s Manual Terex part number 893020 REVA D 2 Check the Tower Rotation Bearing Bolts Note Terex requires that this procedure be performed every 1000 hours or annually whichever comes first Maintaining proper torque on the tower rotation bearing bolts is essential to safe machine operation Improper bolt torque could result in an unsafe operating condition and component damage 1 Lower all four outriggers to the ground and leve
88. r button h repeatedly until the actual hour of the day is displayed 8 Pressthe minute button m repeatedly until the minute of the present hour is displayed 9 Move the Set switch to the program position P to set the desired stop and start time A default time of AM 12 00 will appear A small 1 will appear to the right of the time with a lamp symbol above it 10 Use the day hour and minute buttons to set the timer to the desired start day and time 11 Press the program button P to set the timer for the desired shut off time AM 12 00 will appear in the display with a small 2 to the right Note The lamp symbol will not appear above the 2 12 Use the day hour and minute buttons to set the timer to the desired shut off day and time 13 Move the set switch to RUN PartNo 116478 AL8000HT Light Tower TE RE x Section 4 Repair Procedures September2008 CHASSISCOMPONENTS REV 7 2 3 Remove the ballast box cover fasteners Light Ballast How to Check a Ballast Capacitor ADANGER Electrocution hazard Exposure to high voltage electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Use extreme caution when working with high voltage electrical components AWARNING Electrocution hazard Attempting to service the machine before the capacitors are fully discharged could result in death or serious injury Note Be sure the engine has been
89. rformed quarterly Required maintenance procedures and additional hitch information is available in the Fulton Coupler User Manual Fulton part number F1937 Fulton Coupler User Manual Terex part number 150139 Note Engine specifications require that this procedure be performed every 400 hours Required maintenance procedures and additional engine information is available in the Kubota D 1105 and V 1505 Operator s Manual Kubota part number 16683 89169 Kubota D 1105 and V 1505 Operator s Manual Terex part number 893020 B 9 Perform Axle Maintenance Note Axle specifications require that this procedure be performed quarterly or every 3000 miles whichever comes first Proper axle maintenance following the axle manufacturer s maintenance schedule is essential to good axle performance and service life Failure to perform the maintenance procedures can lead to poor axle performance and component damage Required maintenance procedures and additional axle information is available in the Axis Axle Operator Maintenance Manualincluded with your machine Axis Axle Operator Maintenance Manual Terex part number 116117 PartNo 116478 AL8000HT Light Tower Section 3 Scheduled Maintenance Procedures September2008 TEREX REV A This page intentionally left blank 3 18 AL8000HT Light Tower PartNo 116478 TEREX Checklist C Procedures September2008 Section 3 Scheduled Maintenance Proced
90. rious injury AWARNING Tip over hazard Do not use temporary flat tire repair products 1 Check the tire tread and sidewalls for cuts cracks punctures and unusual wear 2 Check each wheel for damage bends and cracked welds 3 Check each lug nut for proper torque Refer to Section 2 Specifications 4 Check the air pressure of each tire Refer to Section 2 Specifications Section 3 Scheduled Maintenance Procedures TEREX CHECKLIST B PROCEDURES B 4 Perform Hydraulic Oil Analysis Note Terex requires that this procedure be performed every 250 hours or quarterly whichever comes first Replacement or testing of the hydraulic oil is essential for good machine performance and service life Dirty oil and suction strainers may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often Note Before replacing the hydraulic oil the oil may be tested by an oil distributor for specific levels of contamination to verify that changing the oil is necessary If the hydraulic oil is not replaced at the two year inspection test the oil quarterly Replace the oil when it fails the test See E 1 Test or Replace the Hyaraulic Oil PartNo 116478 AL8000HT Light Tower TEREX CHECKLIST PROCEDURES B 5 Perform Engine Maintenance Isuzu Models Note Engine specifications require that this procedure be performe
91. s Electrical Schematics AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray General Repair Process Malfunction Y Identify os Troubleshoot discovered symptoms problem still exists Rem to Perform service problem repair solved PartNo 116478 AL8000HT Light Tower 6 1 TEREX Electrical Symbols Legend BLK Quick terminal T circuits connect Connection no terminal Circuits crossing no connection Diode Battery CB1 Coil solenoid or relay Flashing beacon Hour meter LED F1 Np 25A Fuse with amperage LS3 7 Section 6 Schematics Power unit a R luv1S 3NI9N3 Toggle switch SPDT BAJI WHOSLYTd Toggle switch DPDT Coolant temperature switch normally open 51 N C Starting aid glow plug or flame ignitor September2008 REV A Limit switch Oil pressure switch Circuit brea
92. s to fully remove air from the system 19 Make sure unit is in a clear area during steps 17 and 18 as air in the cylinders can cause sudden movements of the tower Section 3 Scheduled Maintenance Procedures September 2008 REVA E 2 Perform Engine Maintenance Kubota Models Note Engine specifications require that this procedure be performed every 3000 hours Required maintenance procedures and additional engine information is available in the Kubota D 1105and V 1505 Operator s Manual Kubota part number 16683 89169 Kubota D 1105 and V 1505 Operator s Manual Terex part number 893020 AL8000HT Light Tower PartNo 116478 September2008 REV A E 3 Perform Engine Maintenance Kubota Models Note Engine specifications require that this procedure be performed every 2 years Requiredmaintenance procedures additional engine information is available in the Kubota D 1105 and V 1505 Operator s Manual Kubota part number 16683 89169 Kubota D 1105 and V 1505 Operator s Manual Terex part number 893020 Section 3 Scheduled Maintenance Procedures TEREX CHECKLIST E PROCEDURES E 4 Perform Generator Maintenance Note Generator specifications require that this procedure be performed every 4500 hours or every 3 years whichever comes first Required maintenance procedures and additional generator information is available in the Leroy Somer LSA 37 Installation and Maintenance Man
93. solution clogged d Fan belt is loose d Tighten fan belt e Thermostat is bad e Check Replace thermostat 8 Engine runs but the battery a Alternator has failed a Have a trained mechanic inspect voltage is low the alternator 9 Engine runs but the lights will a Circuit breakers are tripped a Reset the circuit breaker not operate b Loose connections in the wiring b Have a trained electrician inspect system the ballast box wiring system Leroy Somers Marathon Generator the capacitor the generator f Engine speed is too low f Have a trained mechanic inspect the engine speed and reset to 1800rpm 60hz the ballast and capacitors the generator bearing or damaged fan blade the generator 11 Lamp will not start a Lamp loose in socket a Inspect lamp base to see if there is arcing at center contact button Tighten lamp Check socket for damage Replace if needed if needed Make sure power is off c Defective ballast c Interchange ballast plugs If lamp starts replace ballast Check for swollen capacitors charred wiring core and coil or other signs of excessive heat d Low voltage d Check line voltage at ballast input Voltage should be within 10 of rating when operating at normal load Increase supply voltage or remove external load Part No 116478 AL8000HT Light Tower 5 3 Section 5 Troubleshooting September 2008 TEREX TROUBLESHOOTING REVA POSSIBLE CAUSE 11 Lamp will not start ballast e The
94. t Genie part number 49612 2 Lubricate the O ring before installation 3 Be sure that the face seal O ring is seated and retained properly 4 Position the tube and nut squarely on the face seal end of the fitting and tighten the nut finger tight 5 Tighten the nut or fitting to the appropriate torque per given size as shown in the table 6 Operate all machine functions and inspect the hoses and fittings and related components to confirm that there are no leaks Seal Loke Fittings tube fitting installed into Steel hose end SAE Dash size Torque SAE Dash size Torque 4 16 ft lbs 21 7 Nm 4 18 ft lbs 25 Nm 6 35 ft lbs 47 5 Nm 6 30 ft lbs 40 Nm 8 60 ft lbs 81 3 Nm 8 40 ft lbs 55 Nm 10 105 ft lbs 142 4 Nm 10 60 ft lbs 80 Nm 12 140 ft lbs 190 Nm 12 85 ft lbs 115 Nm 16 210 ft lbs 284 7 Nm 16 110 ft lbs 150 Nm 20 260 ft lbs 352 5 Nm 20 140 ft Ibs 190 Nm 24 315 ft lbs 427 1 Nm 24 180 ft Ibs 245 Nm AL8000HT Light Tower Part No 116478 September 2008 Section 2 Specifications TEREX REVA SPECIFICATIONS SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual THREAD Grades 2 Grade 8 LUBED LUBED LUBED Nm in tbs Nm I Nm Nm inlbs Nm 44 20 80 9 100 11 3 10 124 140 158 159 147 o 101 120 135
95. t in death or serious injury Note Be sure the engine has been turned off for at least 15 minutes before servicing the machine Use a voltmeter to confirm there is no residual voltage in the capacitors 1 Remove the generator capacitor cover See 6 1 How to Remove the Generator Capacitor Cover 2 and disconnect the wires attached to the capacitor s 3 Usingan insulated conductor or a screwdriver with an insulated handle discharge the capacitor by shorting across the capacitor terminals Repeat for the second capacitor if equipped ADANGER Electrocution hazard Exposure to high voltage electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Use extreme caution when working with high voltage electrical components 4 With an ohmmeter set to its highest resistance scale connect the ohmmeter leads to the capacitor terminals and observe the reading on the meter Then reverse the connections and observe the reading on the meter PartNo 116478 AL8000HT Light Tower TEREX GENERATOR Result The meter indicates a very low resistance which then gradually increases AND a very high resistance which then gradually decreases The capacitor is working W Result The meter indicates a very high resistance which does not decrease The capacitor is faulty and should be replaced Result The meter indicates a very low resistance which does n
96. tank from the fuel containment weldment Component damage hazard The fuel tank is plastic and may become damaged if allowed to fall Note It may be necessary to lower the outriggers to the ground and raise the machine using the outriggers to obtain adequate clearance to completely remove the fuel tank Note Clean the fuel tank and inspect for cracks and other damage before installing it onto the machine Section 4 Repair Procedures September 2008 REVA 4 22 AL8000HT Light Tower Part No 116478 September2008 Section 4 Repair Procedures TEREX REV A CHASSISCOMPONENTS 8 1 Function Manifold Components The function manifold is located next to the hydraulic power unit inside the engine Index Schematic No Description Item Function Torque 1 Solenoid valve 3 position 4 way Eun Light bar up down 25 ft lbs 34 Nm 2 Solenoid valve position 4 way EE Tower extend retract 25 ft lbs 34 Nm 3 Solenoid valve position 4 way Bus Tower up down 25 ft lbs 34 Nm 4 Relief valve Bi directional 1200 psi 82 7 Tower rotate left right 20 ft lbs 27 Nm 5 Solenoid valve 3 position 4 way Gusts Tower rotate left right 25 ft lbs 34 Nm 6
97. te Axle specifications require that this procedure be performed initially and following a wheel change after the first 10 25 and 50 miles Proper axle maintenance following the axle manufacturer s maintenance schedule is essential to good axle performance and service life Failure to perform the maintenance procedures can leadto poor axle performance and component damage Required maintenance procedures and additional axle information is available in the Axis Axle Operator Maintenance Manualincluded with your machine Axis Axle Operator Maintenance Manual Terex part number 116117 Section 3 Scheduled Maintenance Procedures September 2008 REVA A 7 Perform 30 Day Service The 30 day maintenance procedure is a one time procedure to be performed after the first 30 days or 40 hours of usage After this interval refer to the maintenance tables for continued scheduled maintenance 1 Performthefollowing maintenance procedures B 3 Inspect the Tires Wheels and Lug Nut Torque AL8000HTLightTower Part No 116478 September2008 REV A A 8 Perform Engine Maintenance Note Engine specifications require that this procedure be performed every 50 hours Requiredmaintenance procedures and additional engine information is available in the Isuzu 4LE1 Diesel Engine Instruction Manual Isuzu part number IDE 6033 OR the Kubota D 1105 and V 1505 Operator s Manual Kubota part number 16683 89169 S
98. the external snap rings from the tower extension cylinder barrel end pivot pin Use a soft metal drift to remove the pin 5 Slide the extension cylinder towards the tongue end of the machine slightly and carefully remove the cylinder from the machine Crushing hazard The tower AWARNING extension cylinder could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane PartNo 116478 AL8000HT Light Tower TE RE x Section 4 Repair Procedures September2008 TOWERCOMPONENTS REV 3 5 How to Adjust the Tower Tower Rotation Motor How to Remove the Tower Rotation Motor Note When removing a hose assembly or fitting the O ring on the fitting and or hose end must be replaced and then torqued to specification during installation Refer to Section 2 Hydraulic Hose and Fitting Torque Specifications Note Perform this procedure with the tower in the stowed position and the transport lock pin installed 1 Tag disconnect and plug the tower rotation motor hydraulic hoses Cap the fittings on the motor Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 2 Remove the rotation motor pinion gear guard fasteners Remove the guard 3 Remove the rotation motor mounting fasteners Remove the motor from the machine
99. the fasteners securing the generator to the chassis 19 Attach a lifting strap from an overhead crane or other suitable device to both lifting eyes on the generator Support the generator Do not apply any lifting pressure 20 Remove the fasteners securing the generator to the engine bellhousing 21 Remove the generator from the machine Crushing hazard The generator ACAUTION may become unbalanced and fall if not properly supported when removed from the machine Models with Leroy Somer generators 11 Pull the cover off the top of the generator to access the wire harness where it connects to the generator 12 Using an insulated conductor or a screwdriver with an insulated handle discharge the capacitor by shorting across the capacitor terminals Repeat for the second capacitor if equipped ADANGER Electrocution hazard Exposure to high voltage electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Use extreme caution when working with high voltage electrical components 13 Tag and disconnect the wires at the top of the generator Remove the cover AL8000HT Light Tower Part No 116478 September2008 REV A 14 Tag and disconnect the ground wire from the generator mount 15 Use a lifting jack or similar device to support the rear of the engine Do not apply any lifting pressure 16 Remove the generator fan screen from the genera
100. tion box Do not disconnect the main power cables from the junction boxes 3 Remove the fasteners securing each junction box to the light bar light bar lever pivot pin light bar pivot pin light bar connecting link pivot pin cylinder barrel end pivot pin fasteners from the light bar and remove the clamp Lay the hydraulic hoses and main power cables with junction boxes attached over the back of the cabinet 4 Remove the hose and cable clamp retaining d 8 Carelully remove the light bar assembly from the machine 5 Attach a lifting strap from an overhead crane to the light bar assembly Support the light bar Do not apply any lifting pressure Crushing hazard The light bar AWARNING assembly could become unbalanced and fall when removed from the machine if not properly supported by the overhead crane Note During removal the overhead crane strap will need to be carefully adjusted for proper balancing 4 4 AL8000HT Light Tower Part No 116478 September2008 Section 4 Repair Procedures TEREX REV LIGHT BAR COMPONENTS 2 2 Light Bar Lift Cylinder How to Remove the Light Bar Lift Cylinder The light bar lift cylinder raises and lowers the light bar assembly The light bar lift cylinder is equipped with counterbalance valves to prevent movement in the event of a hydraulic line failure Note Perform this procedure with the tower in the stowed position Note When removing a hose assembly
101. tion to learn how to perform these inspections If any inspection receives N tag and remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes acceptable N no remove from service R repaired Checklist Rev Y NR Checklist B Rev A Y NR A 1 Manuals and decals B 1 Battery A 2 Pre operation inspect B 2 Electrical wiring A 3 Function tests Perform every 8 hours B 3 Tires and wheels B 4 Hydraulic oil analysis A 4 Engine maintenance Isuzu models B 5 Engine maintenance Isuzu models A 5 Generator maintenance Perform after 10 miles B 6 Generator maintenance Perform quarterly A 6 Axle maintenance Perform after 25 miles A 6 Axle maintenance Perform after 50 miles A 6 Axle maintenance Perform after 40 hours A 7 30 day service Perform every 50 hours A 8 Engine maintenance Perform weekly A 9 Hitch maintenance Perform every 100 hours A 10 Grease rotation bearing A 11 Engine maintenance Kubota models Perform every 200 hours A 12 Engine maintenance Kubota models B 7 Hitch coupler maintenance Perform every 400 hours B 8 Engine maintenance Kubota models Perform every 3000 miles B 9 Axle maintenance Checklist Rev A YNR C 1 Extend retract cables a
102. tor Note The generator fan screen covers the generator fan blades and is located between the generator andthe engine bellhousing 17 Remove the fasteners securing the generator to the engine flywheel 18 Remove the fasteners securing the generator to the chassis 19 Attach a lifting strap from an overhead crane to the generator Support the generator Do not apply any lifting pressure 20 Remove the fasteners securing the generator to the engine bellhousing 21 Remove the generator from the machine Crushing hazard The generator will ACAUTION fall if not properly supported when removed from the machine 7 1 Ground Controls How to Program the Engine Start Timer machines with auto start option The timer is used to automatically start the engine and turn on the lights at a preset time 1 Move the engine start switch to timed start 2 Onthe timer move the mode switch upper left switch to auto and the set switch upper right Switch to RUN Section 4 Repair Procedures TEREX Chassis Components 3 Using the tip of a pencil or pen press the Reset button R A blinking display will show 0 00 for the time and an arrow under the day 7 for Sunday 4 Move the set switch to the left clock icon to set the present day and time 5 Adefault time of AM 12 00 will appear on the display screen 6 Pressthe day button 1 7 repeatedly until the arrow points to the actual day of the week 7 Pressthe hou
103. ual Leroy Somer part number 3664EN 09 2005 B OR the Marathon Installation Operation and Maintenance Manual Marathon part number GPNO12 OR the Newage Installation Service and Maintenance Manual Newage part number BCH 018 Leroy Somer LSA 37 Installation and Maintenance Manual Terex part number 116118 Marathon Installation Operation and Maintenance Manual Terex part number 116188 Newage Installation Service and Maintenance Manual Terex part number 830001 PartNo 116478 AL8000HT Light Tower 3 29 TEREX CHECKLIST E PROCEDURES E 5 Perform Generator Maintenance Note Generator specifications require that this procedure be performed every 15000 hours or every 19 years whichever comes first Required maintenance procedures and additional generator information is available in the Leroy Somer LSA 37 Installation and Maintenance Manual Leroy Somer part number 3664EN 09 2005 B OR the Marathon Installation Operation and Maintenance Manual Marathon part number GPNO12 OR the Newage Installation Service and Maintenance Manual Newage part number BCH 018 Leroy Somer LSA 37 Installation and Maintenance Manual Terex part number 116118 Marathon Installation Operation and Maintenance Manual Terex part number 116188 Newage Installation Service and Maintenance Manual Terex part number 830001 Section 3 Scheduled Maintenance Procedures September 2008 REVA 3 30 AL8000HT Light Tower P
104. ures REV C 1 C 2 Inspect the Tower Extend Retract Cables and Pulleys Note Terex requires that this procedure be performed every 500 hours or semi annually whichever comes first Detection of damage to the cables or pulleys is essential for safe machine operation An unsafe working condition exists if these components are damaged and do not operate smoothly Regular inspection of this system allows the inspector to identify changes in the operating condition that may indicate damage Note Perform this procedure with the tower in the stowed position 1 Lower all four outriggers to the ground and level the machine 2 Remove the tower transport lock pin 3 Fully extend the tower in a horizontal direction ADANGER Tip over hazard The machine will tip over when the tower is extended if the outriggers are not lowered to the ground 4 Visually inspect the cables and components for the following frayed or broken wire strands kinks in the cable corrosion paint or foreign materials split or cracked cable ends cables are on all pulleys cables at end of adjustment range no broken or damaged pulleys no unusual or excessive pulley wear all fasteners in place and secure Perform Engine Maintenance Note Engine specifications require that this procedure be performed every 500 hours or semi annually whichever comes first Required maintenance procedures and additional engine information is
105. ut This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personnelto potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Indicates an imminently hazardous situation which if not avoided will result in death or serious injury Indicates potentially hazardous AWARNING situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property damage Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps PartNo 116478 AL8000HT Light Tower 3 1 TEREX SCHEDULED MAINTENANCE PROCEDURES Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear atthe beginning of a maintenance procedure it conveys the meaning below Indicates that tools will be required to performthis procedure Indicates that new parts will be
106. vehicles Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Germany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241

AL8000HT Service Manual-116478-07-28-08

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